Robotas Provides Cost-Effective Solution to Aging Axial, Radial, and DIP Insertion Machines
By Georgina Blackwell
For decades, automated axial, radial, and dual in-line package (DIP) insertion machines have been a staple in electronics manufacturing, effectively streamlining the through-hole technology (THT) assembly process. These machines provide fast turnaround times and high precision, making them invaluable for large-scale production. However, as these systems age, manufacturers increasingly face significant challenges in keeping them operational. High maintenance costs, difficulty in sourcing spare parts, and the impracticality of running these machines for small production runs have led numerous facilities to reduce their use of them or even abandon them completely.
Robotas’ Mascot Systems present a highly effective, cost-efficient alternative to aging axial, radial, and DIP insertion machines. By offering a streamlined, semiautomated approach that delivers the same precision and reliability as traditional insertion equipment – at a fraction of the cost – Robotas provides manufacturers with a viable solution to sustain their THT operations.
Many electronics manufacturers still rely on their aging axial, radial, and DIP insertion machines, but maintaining these systems has become increasingly difficult. Key challenges include:
• Obsolete and Expensive Spare Parts: With original manufacturers discontinuing support for older models, spare parts have become scarce and costly. Sourcing necessary components often leads to extended downtimes and operational inefficiencies.
• High Maintenance Demands: Keeping aging equipment operational requires frequent servicing, calibration, and troubleshooting. Many companies find that their insertion machines are only operational intermittently – sometimes just once or twice a week – due to these maintenance demands.
• Limited Justification for High Investment Costs: While high-volume manufacturers may still benefit from traditional insertion machines, companies with lower production volumes struggle to justify the expense of replacing outdated equipment with new, fully automated systems.
These limitations have forced companies to either scale back their THT production or seek alternative solutions that provide the same quality and efficiency without the financial strain.
For manufacturers looking to maintain high-quality THT assembly without the excessive costs associated with aging insertion machines, Robotas’ Mascot Systems provide an ideal and up to date alternative. Designed to optimize manual and semiautomated insertion processes, Mascot Systems offer a lower investment cost while ensuring precision, reliability, and ease of use. Key features include:
1. Enhanced Component Placement Accuracy: Robotas’ Mascot Clinch Conveyor streamlines the THT assembly of PCBs using an electrostatic discharge (ESD)-safe, SMEMA-controlled motorized conveyor. The integrated clinch technology allows component leads to be bent in any direction (360°) and at various angles (from 35° to 85°), ensuring secure placement and preventing component dislodgment during the wave soldering process.
2. Optimized Operator Guidance: Robotas’ Carousels and Dynamic Pick-to-Light Arrays automatically present required components to the operator at every step of the assembly process. The Mascot software and laser guides operators on polarity and placement, reducing errors and improving efficiency.
3. Reduced Setup Time and Improved Flexibility: Traditional axial and radial insertion machines require extensive setup for each PCB assembly, making them cost-effective only for large production volumes. Mascot Systems eliminate these lengthy setup times, allowing for quick changeovers and making them ideal for manufacturers with varied and low-to-medium production volumes.
4. Automated Verification for Error Prevention: The new Mascot Verify Camera Module captures images to verify component presence, absence, and polarity before soldering, virtually eliminating human error and reducing rework costs.
5. Up to Date, Dynamic Solutions: Robotas’ Mascot systems run on up-to-date Windows 11 Pro Operating systems. Mascot Spare Parts are also readily available, making system maintenance easy and accessible for manufacturers all around the world.
While automated insertion machines are known for their precision and speed, their high investment costs, long setup times, and maintenance challenges make them impractical for many manufacturers. Robotas’ Mascot Systems provide a positive alternative by delivering the same high-quality results at a significantly lower cost. Key benefits include:
· Lower Capital Investment: Unlike fully automated insertion machines, which require substantial financial outlays, Mascot Systems offer a cost-effective way to maintain THT assembly operations.
· Reduced Maintenance and Downtime: With fewer mechanical components and simpler operational requirements, Mascot Systems minimize downtime and maintenance costs.
· Increased Flexibility for Small Production Runs: Companies that need to produce smaller batches of axial and radial insertion tasks can continue operations efficiently without justifying the expense of high-volume equipment.
· Efficiency: The intuitive, guided component placement process ensures accuracy and speed without the need for extensive training.
Conclusion
As aging axial, radial, and DIP insertion machines become more costly and difficult to maintain, manufacturers need an alternative that offers the same precision and efficiency without the high investment and upkeep expenses. Robotas’ Mascot Systems provide a streamlined, flexible, and cost-effective solution, ensuring manufacturers can continue producing high-quality THT assemblies without having to use obsolete equipment. By leveraging advanced operator guidance, automated verification, and optimized component placement, Mascot Systems deliver a modern approach to insertion processes – helping manufacturers stay competitive while keeping costs under control.
For more information about Robotas Technologies Ltd., contact Georgina Blackwell, Product Design & Marketing Engineer, at Unit 4 Thirkill Park, Thirkill Drive, Pannal, Harrogate, HG3 1GQ. UK; +44 (0) 1474 815 815; E-mail: sales@robotas.com – Web site: www.robotas.com.