Hotbar Reflow Soldering
LOROM advanced software controlled Pulsed Heat Hot Bar Reflow Soldering System is a fully integrated, hot-bar system that utilizes a pulsed heat thermo technology for hot bar reflow soldering applications.
The LOROM equipment consists of ergonomically in house designed models with optional product handling features such as linear slides and rotary tables.
Hot bar bonding systems are “customizable” to suit the customer’s specific technical requirements via optional plug & play modules.
All of our systems are configured with full automatic process control with manual or semi automatic loading of parts.
All process parameters are embedded into the system, ensuring consistent process quality and operator independence offering maximized production output.
Our Pulsed Heat Reflow Soldering is a selective soldering process where two pre-fluxed, solder-coated parts are heated with a thermode to a sufficient temperature to melt the solder. After this the parts are cooled below the solidification temperature to form a permanent electro-mechanical bond.
The LOROM software controlled precision temperature control units provides targeted heating and precision temperature control for applications such as the connection of flexible circuits, ribbon cables, wires, single or dual sided edge connectors.
The temperature control systems includes:
- Closed-loop temperature and time control
- In excess of 60 various heating profiles
- Remote programming
- Thermocouples for process control and auxiliary monitoring that can be stored as quality assurance and control measures
Automatic Tip Soldering
Features
- Solder feed / reverse amount is adjustable in 0.1 mm increments
- Solder pre-heat / heat time is adjustable in 0.1 second increments
- Designed to minimize cycle time by using customized programs
- Specialized programs achieves much shorter tact/cycle time
- Temperature controller raises iron temperature to 350° in approximately 10 seconds
- Automatic temperature calibration function improves iron tip performance and stability
- High precision thermocouple is built into the Apex of the iron tip so minimal temperature drop can be detected and recovered quickly
- Innovative heater cartridge design is equipped with built-in thermocouple which provides excellent thermal efficiency with high-performance 130W heater
- Heater cartridge incorporates quick-change iron tip to meet end-user requirements for reducing consumable supply costs while maintaining superior performance
Infra Red Soldering
In-house developed and build IR soldering lines provides a fast and cost effective high quality solder.
Our decades of design experience of creating the perfect solder joint is helped us develop this unique high speed soldering technology.
The IR soldering technology in combination with automatic applicators of solder paste enables multiple conductors being soldered simultaneously on two side connectors with unmatched speed compared to other soldering technologies.
Crimp Force Monitoring
LOROM – creating the perfect connection.
During the crimping manufacturing process the force of the crimping is monitored and tested.
The test immediately determines whether or not a crimp is good based on predetermined force and height parameters.
Our advanced crimp force monitoring system consists of a load cell to measure crimp force, a triggering device that initiates reading of force measurement and a control unit to analyze the data.
The LOROM crimp force monitoring and test system is used on our automated crimping machines as well as our standard on crimp presses.
Crimp Height
Prior to any crimp of terminals the crimp height is entered into the control unit.
Crimp height is determined either with a visual inspection system or manually with a micrometer, Determining dimensions from the crimp top and the crimp bottom.
This measurement is taken in the center of the crimp.
Once crimp height is determined, software in the control unit automatically calculates required crimp force and converts it into a curve over time that represents the perfect crimp.
With programming complete, the operator now teaches our advanced system to use the perfect crimp curve as a reference force. Each subsequent crimp is compared with this force. A bad crimp is one that deviates from the reference force.
In line crimp force measurement systems
LOROM has the option for in process crimp analysis via software for crimp curve analysis with possibility of statistical version storing measurement data to our mainframe computer.
Pull force measurement systems
Measures pullout forces up to 1000 N with accuracy of 0.03 N deliver precise and reproducible results. . This advanced sensitive maintains the pullout speed constant.
The tester can be connected via interface software to our mainframe computer for statistical data collection.
Crimp height measurement system
Integrated crimping height measurement system with automatic correction based on advanced software algorithms adjustment based on real measurement data.
The system corrects the crimp height automatically, eliminating the need for operators to make calculations in their heads and to adjust the crimping height manually by hand.
Significant cost advantages by reducing conversion time without compromising crimp quality.
With more than 500 engineers and in-house tooling design and fabrication, ramp up is extremely short enabling our customers to meet vital time-to-market time frames.
Furthermore our in house software department, tooling and machinery division eliminates/reduces down time of production lines ensuring low cost, high productivity and yield reducing total cost.
All machinery and tools are on very excessive schedule preventive maintenance programs ensuring the perfect connection at all times.
Our software engineering team, have the capability to provide software meeting customer specific SPK data collection requirements.
Cable termination
Our LOROM IDC wire termination equipment is used for medium to high volume production of cables with IDC connectors.
Our equipment is manual or semi-automatic; the line operator presents 1 (up to 2 wires).
Elimination of human error is a big issue for LOROM, advanced wire recognition systems are implemented in our IDC equipment ensuring automatic wire selection identifying conductor and that it is in the right termination slot prior to the operator activating the termination.
The machine will cut the wire to length, inserts them in the IDC connector slots and automatically position the connector block to the next termination
Micro Welding
Especially as miniaturization continues and connector sizes decrease below 0.004-in. thickness for flat planar cables and wire diameters used micro coaxial cables as the LOROM MCX series, traditional processes such as crimping, soldering and brazing become less viable due to high joint resistance, questionable joint reliability and longevity.
By contrast, welding, which provides excellent joint integrity, longevity and conduction performance, is quickly becoming standard. The technology required to join two materials where at least one is less than 0.02-in. in thickness is called micro welding.
LOROM micro welding technologies are designed to meet challenges of welding copper of how to control the heat balance in these small and highly conductive parts ensuring no over- or under-heating.
Examples of applications where LOROM welding technologies has proven value are, the automotive industry has seen a significant increase in sensor technology to monitor car performance, function and environment. Each sensor has many terminal connections that must survive for the lifetime of the car. In this arena, laser micro welding offers a viable option, and the laser provides a great tool for high speed high quality welding.
Connection requirements are also critical in the medical industry, for example in implantable devices, sensing and monitoring instruments, where each connection is critical to maintaining part function and performance and thus requires a highly stable joining technology.
Similarly, in the communications industry, signal strength and integrity are crucial to maximize part performance and ensure that the joint is not a limiting factor to the part’s design.
LOROM Soldering Robots
Our soldering robot provides a flexible and easily customized soldering technology through software programming as well as build in teaching functions.
The controller can store in excess of 100 solder profiles to meet the needs of a wide variety of soldering applications.
The robot’s more than 250 X-Y programs (30,000 points total), provides endless flexibility.
Automatic Soldering
Crimping
Most terminal manufacturers supply crimping instructions and specifications, however very often very general and incomplete in all application instances and are general in nature.
Applying decades of extensive engineering and specific various customer application knowledge we have developed own excessive application-specific specifications. Following industry standards is a given, hence we exceed international specifications i.e. UL 486A-486B, IPC/WHMA-A-620, SAE AS7928 for the military and automakers, as well as VW 60330 standard by Volkswagen.
LOROM high performance quality crimp meets or exceeds performance specifications related to crimp force, height and width; pullout force; strip length; and insulation window (area between the wire and insulation).
Semi-Automatic Crimping
On the factory floor Crimp termination quality assurance lab
In our modern state-of-the-art production environment ensuring quality fast and reliability test of our crimp terminations is a competitive advantage with our “on the factory floor labs.”
Especially in the production of cable harnesses, reliability and high speed are of equal concerns.
Micrograph Inspection
A micrograph is a photo of a crimped terminal cross-section taken by a microscope. A micrograph inspection involves analyzing this photo to measure crimp height and width; determine whether or not the crimp is gas tight (no voids within the strands); and if and why there is terminal deformation.
Our fast and reliable micrograph analysis equipment saves costs and reduces rejects.
The micrograph laboratory equipment in our labs analyses and documents the quality of crimp connections by means of brilliant colour photographs. Micrographs are indispensable for the release of new crimp contacts and crimping tools.
Our track record proves that micrograph lab’s and equipment are a vital component for state-of-the-art quality engineering.
The system consists of equipment that provides vital data:
- Automatic cutting + polishing module
- Etching module and full size imaging for accurate cross-section analysis through
- Evaluation & Documentation integrated into our mainframe
Fully Automatic Crimping
With more than 40 fully automated Cut-Strip and crimp machines, we are ready for any high volume high quality customer opportunity.
We are currently employing our fully automated machinery in diverse markets such as:
- Automotive wiring systems and harness
- Airbag oxygen sensor assemblies
- Medical applications, High volume such as disposable cable assemblies
- Brown goods, professional audio and video
- White goods, house hold appliances
- Industrial systems
- Consumer electronics
- Data & Telecommunication systems
- Commercial airframe frame wiring systems
- Gaming machines
- Vending machines and cash dispensing systems
- Point of sale equipment
- Security and alarm systems
IDC
The IDC connection is the fastest way to install a wire, and is one of the most cost effective solutions.
In the insulation displacement technique, an insulated wire is pressed into the cutting zone of a fork contact. This cuts the insulation and produces a reliable connection between conductor and the cutting metal.
Benefits
- A particularly easy and time-saving connection method
- Constant conductor clamping force independent of the operator
- No special tools needed to connect the wire
- High consistency of contacting quality
- Excellent suitability in environmental conditions with thermal and mechanical loads (especially vibration)
- Stability of the contacts themselves (therefore particularly suitable for PoE applications).
- Mechanical stability,
- Gastight and dust tight, elimination of deposits or oxidation at contact points
Resistance Welding
Resistance welding uses the weld interface’s high resistance to create heat as current is passed through the parts. The circuit is created by electrodes that contact the part either from the same side or opposite sides of the work pieces. Electrical contact is assured by exerting some force on the parts.
When resistances welding conductive parts, the electrodes are resistive and therefore perform two functions: they heat up and conduct heat to the parts and they conduct sufficient current to enable some heating to occur at the joint interface.
Resistance welding works well for a variety of joining applications and materials. However, since this process relies on mechanical contact and the need to create an electrical circuit between two electrodes, it may not work properly in all circumstances, especially if the parts are mechanically delicate. In addition, the minimum electrode size is around 0.04-in. in diameter, and so this may limit joint accessibility.
