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Part insertion, equipment tooling considerations, even paste placement for paste-in-hole technology will be largely unaffected by the change of solder alloy As noted previously, in spite of the higher liquidus temperature, hand-soldering iron tips and wave-soldering pots will use similar temperatures The design engineer will have to address the generally poorer solderability of Pb-free alloys, which arises from the higher surface tension of the solder Flux selection and alternative surface finishes can mitigate this discrepancy to some degree Other measures may be necessary For example, the designer may be required to increase the spacing between components in order to avoid solder bridges that cause short circuits during wave and selective soldering The high Sn content of Pb-free solders results in a greater degree of erosion of the Cu features on the circuit board.

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This phenomenon is particularly severe at the knee of the through hole when the molten solder is highly agitated such as in a wave-soldering or selective soldering machine Therefore, it may be necessary to reduce the time that the joint is exposed to the molten solder or to select an alternative Pb-free alloy (Sn-Ag-Ni or Sn-Ag-Ni-Ge) that is less prone to Cu erosion..

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Assembly Process The through-hole printed circuit board can be a cost-effective technology for many applications. One determining factor is the level of automation used to make the product, which can range from hand assembly to fully automated processes (inline or batch). The specific assembly steps include component insertion (also referred to as board stuffing ), lead trimming, soldering, and post-assembly cleaning. Labor costs, capital expenditures, board design, and production volumes are contributing factors toward determining the details of these steps. There are two general formats for assembly processes: the cell or batch process and the line process. Both methods are discussed in the following subsections. 40.2.3.1 Cell (Batch) Process. The cell process routes the circuit boards in batches between the different steps. The cells or workstations are not always in immediate proximity to each another and can be entirely manual, semiautomated, or fully automated in terms of the actual process step. For example, component placement may be fully automated, but require several machines for inserting the different component types. Circuit boards are typically loaded and unloaded by hand between machines. Table 40.1 lists the advantages and disadvantages of the cell process. The cell or batch process is best suited for a facility that assembles a high mix of low production volume products (e.g., prototype development or high-reliability circuit boards) where flexibility is necessary on the factory floor.

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TABLE 40.1 Advantages and Disadvantages of the Cell Process Advantages Single machine outage does not immediately stop the entire process line. Adds greater flexibility to the process by creating alternative workflow routes. Attractive for high-mix, low volume applications that require frequent equipment change-outs and re-tooling. Disadvantages Higher product flow time due to the transfer of parts between cells is unattractive for high volume applications. Part transfer between cells increases the likelihood of handling damage Difficult to predict product line throughput in a multi-cell assembly process.

40.2.3.2 Line Process. The second approach is the line process, where the different insertion machines, as well as the soldering process in some cases, are linked together with automatic board-handling equipment. Table 40.2 lists the advantages and disadvantages of the line process line. The line process is best suited for a factory floor where high production volumes (e.g., consumer electronics) and a low mix of product types are typical of the manufacturing operations. Less versatility is required by assembly processes, which justifies the capital equipment expense.

There are two more Einstein s equations in this example that could be used for further analysis. We simply state them here: 2 R R b =0 r t t r e 2b(t,r ) R b R 2b(t,r ) 2 R R b 2 + e t t r r r + 2 =

TABLE 40.2 Advantages and Disadvantages of the Line Process Line Advantages Improved manageability of material inventory, product flow, and operator resources is attractive for high volume, low mix applications. Shorter process times by eliminating the transfer of parts between machines. Reduce the likelihood of handling damage to the assembled product. Disadvantages Failure or maintenance outage of a singe machine failure can potentially halt an entire assembly line. Reduced equipment flexibility is unattractive for high mix assembly. Capital equipment costs and fixed floor space requirements are critical considerations.

The configurations of most through-hole components fall into one of three geometries: axial leaded, radial leaded, and dual inline pin (DIP) packagesThese traditional configurations are used for resistors, capacitors, transistors, crystals, and, in the case of active devices, the DIP package There are also odd-form packages for devices such as transformers, switches, and relays New package configurations such as the pin grid array (PGA) are being developed to accommodate the increased functionality and further miniaturization of active devices Besides the actual component body size, shape, and lead configuration, the other factor that can impact the through-hole assembly process is the lead finish First of all, the finish can potentially add significantly to the diameter of the lead, which must be taken into account when considering the tolerance budget for the hole in the board design.

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