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PIN INSERTION

Pininsert 2100 is a pneumatic or servo-drive table-mount machine for semi-automatic pin insertion into various electrical components. It was designed as stand-alone or inline machine for small and medium production volumes (up to 3 600 pins per hour).

Components are located on the manually-adjustable working table. Operator moves it to the work zone where pins are inserted one at a time in automatic (option), step-by-step and manual operation modes. Table can be motorized on demand.

Interchangeable insertion head makes it possible to produce various applications on one machine.

Camera and laser control assures correct positioning of the components and pin.

Technical characteristics

Power supply 220 V. 50 Hz single-phase 10 A
Power 0.5 kW
Air pressure 6 b
Instantaneous cycle time 500 ms/pin
Max pin’s length (standard version) 25 mm
Max pin’s length (long version) 60 mm
Max pin’s cross section 1.5 mm
Time of head insertion change 10 min
Time of set of part change into insertion head 15 min
Standard motorized X axis (option) 150 mm stroke
Standard motorized Y axis (option) 150 mm stroke
Weight (basic) ? kg
Dimensions (WxDxH) 400 x 400 x 700 mm
CE conformity  ✓

STANDARD FEATURES

Insertion head
Insertion head, pneumatic or servo motor, comprises of tool set, which could be changed to another one according to the application.

There are several types of insertion heads according to the pin types: end-to-end, right angle, U-band (bandolier) or terminals.

Insertion accuracy is highly stable and equals ±0.05 mm (CPK > 1.68). When using servomotor, insertion depth is controlled by encoder.

Insertion technique involves the use of precut round or square wire with acceptable section from 0.3 to 1.5 mm (with servo-drive head) or 1 mm (with pneumatic head).

Indexation system
The pin is fixed in the insertion head one step before cutting position, which decreases the tolerance of pin length and thus provides cutting and insertion precision.

Pins unreeling systems
There are various pin feeding systems according to each pin type: end-to-end pins floor-mount unreeler, carrier pins unreeler for bandolier pins, terminal unreeler.

Options

Frame & cabinet

Machine and all its components can be integrated into floor mount frame with PLC and HMI units for operation control.

Lighting & safety beams

Safety beams can be installed on the frame to detect foreign object presence and to stop the machine. This feature as well as work area lighting guarantees operator’s safety.

Vibrating feeder for connectors

Option for in-bulk connectors feeding. A bulk supply hopper automatically doses parts into the vibratory bowl and inline vibrating conveyor.

Alignment supports for components

Work table can be equipped with alignment supports. Components are mount onto this support to simplify its positioning.

Automatic motorized positioning

Pininsert 2100 could be equipped with motorized table. In this case its movement to the work area (X axis) and/or from one insertion position to another (Y axis) is performed automatically with a step motor.

Components position laser control

Components position laser control detects wrong positioning, sends an error message on the screen and doesn’t let the machine work till the component is placed correctly.

Low/high definition camera

Camera with integrated logics for pin insertion height control. Choice of definition depends on the dimensions of the components.

Pin presence laser control

Pin presence laser control lets the machine differ empty slots and already inserted pins. New pins are inserted into the empty slots only and other positions are skipped.

Insertion force control

System controls each insertion and compares it to the reference values of insertion force. In case of deviation machine stops automatically or gives an alarm sound.

Force data export to Excel

System allows to download all the insertion data in Excel format.

Poka Yoke

Parts indicated by laser or insertion force sensor as defective are to be thrown into special container. Until these parts are detected inside of the container, the machine wouldn’t continue operation.

Barcode reader

Pininsert 2200 is a CNC floor-mount machine for semi-automatic pin insertion. It was designed for high production volumes: up to 8 000 pins per hour with a single insertion head and up to 15 000 pins with a double head.

Supervised by PC and having fully programmable insertion height, Pininsert 2200 can be integrated into a production line or operated as a stand-alone unit.

Pininsert 2200 can be optionally equipped either with universal clamps for PCB or with Y table and adapting fixtures for plastic connectors.

Technical characteristics

Power supply 220 V. 50 Hz single-phase 10 A
Power 2.0 kW
Instantaneous cycle time 500 ms/pin
Max pin’s length (standard version) 25 mm
Max pin’s length (long version) 60 mm
Max pin’s cross section 1.5 mm
Time of head insertion change 10 min
Time of set of part change into insertion head 15 min
Standard motorized X axis (option) 400 mm stroke
Standard motorized Y axis (option) 400 mm stroke
Weight (basic) ? kg
Dimensions (WxDxH) 1200 x 1200 x 1600 mm
CE conformity  ✓

STANDARD FEATURES

Pins unreeling systems
There are various pin feeding systems according to each pin type: end-to-end pins floor-mount unreeler, carrier pins unreeler for bandolier pins, terminal unreeler.

Universal table for PCB
400×400 mm universal table includes movable clamps to fix PCB plates of various dimensions and 10/20 mm stroke anvil to support PCB at insertion point. Thanks to it there is no need to change fixture when changing to new application.

Y table for plastic connectors
Y table allows to load special removable fixture for plastic connectors. Fixtures have centering finger for correct positioning and can be equipped with alignment supports that will fix each connector.

Using two fixtures speeds up the process: while one is operated, operator loads the components to the second one.

Electrical insertion head
Electrical insertion head is fully interchangeable which simplifies change to the new application. There are several types of insertion heads according to the pin types: end-to-end, right angle, U-band (bandolier) or terminals. Insertion accuracy is highly stable and equals ±0.05 mm (CPK > 1.68).

Insertion depth is controlled by encoder and can be programmed to one-hundredth of a millimeter in the PC editor whereas equipment of other brands should be mechanically set. Thus there is no need in mechanical adjustment for each new series.

Insertion technique involves the use of precut round or square wire with acceptable section from 0.3 to 1.5 mm (with servo-drive head) or 1 mm (with pneumatic head).

Indexation system
The pin is fixed in the insertion head one step before cutting position, which decreases the tolerance of pin length and thus provides cutting and insertion precision.

Easy-to-operate PC interface with standard PC keyboard & mouse

Options

Lighting & safety beams

Safety beams detect foreign object presence and stop the machine. This feature as well as work area lighting guarantees operator’s safety.

Automatic components loading/unloading

Electrical belt conveyor to load and unload components to/from Pininsert set in line with other equipment.

Components position laser control

Components position laser control detects wrong positioning, sends an error message on the screen and doesn’t let the machine work till the component is placed correctly.

Insertion height camera control

Low/high definition camera with integrated logics for pin height insertion control.

Insertion camera control

Special camera determines the position of 3 extreme holes in the PCB and, on this basis, calculates the position of all the holes and insertion points correspondingly.

Pin presence laser control

Pin presence laser control lets the machine differ empty slots and already inserted pins. New pins are inserted into the empty slots only and other positions are skipped.

Insertion force control 

System controls each insertion and compares it to the reference values of insertion force. In case of deviation machine stops automatically or gives an alarm sound.

Force data export to Excel

System allows to download all the insertion data in Excel format.

Poka Yoke

Parts indicated by laser or insertion force sensor as defective are to be thrown into special container. Until these parts are detected inside of the container, the machine wouldn’t continue operation.

Barcode reader

Pininsert 2200 CV (Conveyor Version) is equipped with SMEMA compatible belt conveyor system to enable integration of equipment into the production line of surface-mounted printed circuit boards.

It can be manufactured as DH (Double-Head) version with two heads to insert pins of different dimensions within a cycle without readjustment.

Technical characteristics

Power supply 220 V 50 Hz 10 A
Power 3.0 kW
Air pressure 6 bar
Instantaneous cycle time 500 ms/pin
Pin max length (standard version) 25 mm
Pin max length (long version) 60 mm
Pin max cross section 1.5 mm x 1.5 mm
PCB dimensions min 50 x 50 mm, max 400 x 400 mm
Time of insertion head change 10 min
Time of set of part change into insertion head 15 min
Standard motorized X axis (option) 400 mm stroke
Standard motorized Y axis (option) 400 mm stroke
Weight (basic) app. 1500 kg
Dimensions (WxDxH) 1860 x 1730 x 1670 mm
Conveyor height from the floor 350 ± 30 mm
CE conformity  ✓

STANDARD FEATURES

Pins unreeling systems
There are various pin feeding systems according to each pin type: end-to-end pins floor-mount unreeler, carrier pins unreeler for bandolier pins, terminal unreeler.

Conveyor table
Adjustable table enables pin insertion into PCBs, which have length and width from 50 to 400 mm and thickness from 0.5 to 4 mm.

It is fitted with universal clamps for PCB plates and anvil supporting a plate from the bottom at insertion point. Thanks to it, there is no need to change fixture when changing to application with different dimensions.

Conveyor control interface is SMEMA-compatible. This allows integration of the machine into the assembly line of surface-mounted PCBs and product traceability system.

Electrical insertion head

This head is fully interchangeable that simplifies change to new application. There are several types of insertion heads according to pin types: end-to-end, right angle, U-band (bandolier) or terminals.

Insertion accuracy is highly stable and equals to ±0.05 mm (CPK > 1.68).

Insertion depth is controlled by encoder and can be programmed to one-hundredth of a millimeter in the PC editor whereas equipment of other brands should be mechanically set. Thus there is no need in mechanical adjustment for each new series.

Insertion technique involves the use of precut round or square wire with acceptable section from 0.3 to 1.5 mm (with servo-drive head) or 1 mm (with pneumatic head).

Indexation system
The pin is fixed in the insertion head one step before cutting position, which decreases the tolerance of pin length and thus provides cutting and insertion precision.

Easy-to-operate PC interface with standard PC keyboard & mouse

Options

Lighting & safety beams

Safety beams detect foreign object presence and stop the machine. This feature as well as work area lighting guarantees operator’s safety.

Laser control of components position

This option allows to detect wrong positioning, sends an error message on the screen and doesn’t let the machine work till the component is correctly placed.

Insertion height camera control

Low/high definition camera with integrated logics for pin height insertion control.

Insertion camera control

Camera checks position of basic holes in PCB. According to this data the program corrects installation positions of pins. In that way errors in PCB production are compensated.

Pin presence laser control

This system lets the machine differ empty slots and already inserted pins. New pins are mounted into empty slots only and other positions are skipped.

Insertion force control

System controls each insertion and compares it to the reference values of insertion force. In case of deviation machine stops automatically or gives an alarm sound.

Poka Yoke 

Parts indicated by laser or insertion force sensor as defective are to be thrown into special container. Until these parts are detected inside of the container, the machine wouldn’t continue operation.

Force data export to Excel

System allows to download all the insertion data in Excel format.

Data Matrix barcode reader

For program autochange.

Pininsert 2500 is a connectors assembly equipment for cutting, 3-angle bending & simultaneous insertion up to 10 pins into the PCB or plastic parts.

All the parameters of Pininsert 2500 processing were verified with the help of FEA simulation and tests: bending tooling shape, pin cutting principle, Y-axis acceleration while transfer, insertion force, etc.

Operation principles:

  1. Pin wires are unreeled
  2. Wires are cut to separate pins
  3. Pins are bend
  4. Pins are inserted into PCB or plastic connector

Technical characteristics

Power supply 220 V. 50 Hz single-phase 10 A
Power 2.0 kW
Instantaneous cycle time 3-4 sec for 4 bended pins/pin
Max pin’s length (standard version)
Max pin’s cross section 1.5 mm
Weight (basic) ? kg
Dimensions (WxDxH) 1200 x 1200 x 1600 mm
CE conformity  

STANDARD FEATURES

Inline integration
Pininsert 2500 was designed to be integrated into existing connector assembly machine: PCB or another connector is prepared by the main conveyor and pin manipulations are performed by Pininsert 2500.

Up to 4 pin line unreeling & feeding systems
Up to 4 pin wire bobbins could be installed on the unreeler – according to the quantity of pins in one final product item. Bobbin diameter is 800 mm, capacity – 200 000 pins.
Pin wire is unreeled with motorized unreeler and lead in rows (up to 4) through brass tubes to the bending station.

4 pin line bending systems
The device cuts the pin line, pre-bends the pins by 90°, arranges them in 4 rows (one pin in a row), completes the bending of the pins’ ends and transfers them to the insertion unit.

Insertion system
Insertion unit is equipped with 2 digitally controlled axis and anvil, which are powered by a brushless servo motors. All insertion points data is visualized on the screen. Mechanical gripper operated by a pneumatic air cylinder positions up to 4 pins from the bending station to the second electrical component.

Options

Cameras for feeding & insertion unit

One camera controls feeding of pins for slippage or breaking. Another detects the pin presence and correctness of their location. Insertion takes place only when the camera identifies correct positioning.

Up to 4 pin line selector

Electro-mechanical switch for the pins allows to select from 1 to 4 pins to be processed.

Additional 2 pin line systems

If there is a necessity to process more than 4 pins, it possible to install additional feeding, bending and insertion systems.

Bending & insertion force control

Insertion force monitor allows to control the force during the bending and insertion for missing or broken pins.

ALTERNATIVE ENERGY

AUTOMOTIVE

ELECTRONICS

PRINTING INDUSTRY

TELECOMMUNICATIONS

TEXTILE INDUSTRY

PIN & COIL FRAME

PIN & METAL

PIN & PCB

PIN & PLASTIC COMPONENT

PIN & PLASTICS COMPONENT & PCB

CUSTOMIZED CONNECTORS

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