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Axial Insertion

This is the process by which leaded through-hole components (mainly resistors, diodes and inductors) are automatically inserted into the holes of conventional printed circuit boards and mechanically fixed in place by the under board clinching of each component's leads. This is where the term 'board stuffing' originated from.

One type of axial insertion machine is known as a VCD or Vertical Centred Distance machine. VCD's are available in two main forms, Stand Alone or Combi-Machine.

The Stand Alone machine requires to be fed with pre-sequenced components on a reel produced by a machine called a Sequencer. The Sequencer machine is set up with reels of all of the unique components required to be inserted into the PCB. Some Sequencers can have in excess of 100 component stations and are modular in format so additional stations can be added or reduced as required.

User programmable software determines when each component head 'fires'. As each head fires, it cuts off the desired number of components from the component reels in the required sequence and individual components drop into a conveyor which travels along the length of the sequencer machine. At the end of the conveyor the components are then re-taped in the pre-determined sequence determine by the software by being sandwiched between adhesive tape to form a 'bandolier'. It is this bandolier or reel which is then fitted to the VCD machine for insertion. Each reel will contain a pre-determined number of sequences. For example one reel may have 40 sequences on it which will be the exact quantity to populate 40 PCBs.

The VCD machine is set up by loading the correct tool plate (which supports and houses the PCB through the insertion process), the sequenced reel and the correct software. Upon activation of the VCD machine, a mechanism cuts the component leads from the tape, forms the leads at a right angle to the component body, and then inserts the leads of each component into its correct position in the PCB. A cut 'n' clinch mechanism cuts and forms the leads protruding through the solder side of the PCB to mechanically fix the component in place. Note, the components are mechanically fixed but not soldered at this stage so electrical connection is not achieved by this process.

The combi-axial insertion machine combines the capabilities of both the sequence machine and the VCD.

VCD machines can typically handle axial components with 5mm-20mm pitch but need to be set up individually to handle one component pitch size at a time.

Capital Equipment Topics

Axial Insertion

Radial Insertion

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Guide Written by Paul Wilson

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