Multi-spot Hot-bar Soldering Process Parameters Optimization

Foxconn ScienceTechnology Group is a electronic connectors and cable products manufacturer serving to global PC (Personal Computer PC) industry. Faced with the increasing cost of raw materials, manpower costs and the introduction of the new labor law, electronic connectors and cable manufacturers in order to maintain and improve the existing profit margin of products, it is necessary to make the production automation and process optimization, reduce working hours; improve product through rate ( passing rate) and reduce production scrap in order to continuously reduce production costs and enhance the competitiveness of products.The paper described the main welding means of cable connector, Hot-bar welding characteristics and its applications in the PC industry. In the fierce competition of PC component industry, the connector manufacturers are actively applying automatic welding methods and optimize welding process to improve the product quality. Among them there are the American Tyco (Tyco), Japanese Marunix (Marunix), Taiwan Wanshih (Wanshih), Hi-teck (Hi-teck), Acon (Acon) connector assembly and manufacturers have been used Hot-bar Welding in production. In addition, since the notebook is developing toward the light, thin, small direction, corresponding the requirement is put out to the cables Conn. manufacturer, the direction of product developing also toward smaller, thinner, thus it requires that Conn. Welding level will be higher. since the a number of advantages of technology and its temperature stability of Hot-bar soldering, which has become the main direction of automatic welding.Base on the actual demands applying the Hot-bar welding to replace the original manual handle in the Foxconn connectors welding production line, in the paper the feasibility of applying Hot-bar welding to replace the manual welding was investigated. The a statistical analysis of the Conn.Hot-bar welding's present situation is carried, the main forms of poor joints made by Conn.hot-bar welding is divided and analyized, the paper picked out the significant parameters of the Conn.Hot-bar welding, which were taken by the assumption verification. Before the seeking main factors test, the temperature of machine was verified and set up the regression analysis between it and the volume of measured resistance, so the effective control of cable connector welding temperature would be realized. After the picking out effect factors, two significant factors :"welding time" and "welding temperature" was only left , then using the response surface design to do the optimization process and find the Optimal welding parameters , and optimized welding parameters are adopted to the actual welding production to confirm its effective. Through the actual welding experiment of production line, the defective rate of Conn. Hot-bar soldering is reduced about 10 percentage contrast with original statistic. From an economic point of view, each year save over 100 million RMB. At the same time, it enhances the production line yield and reduces production costs and increases the product's market competitiveness.