English Views: 0 Author: Site Editor Publish Time: 2025-05-08 Origin: Site
Power switches—particularly those used in industrial and high-voltage environments—require robust and reliable PCB assemblies. These products often include large electrolytic capacitors, transformers, and custom connectors, all of which pose challenges to traditional assembly techniques. Through-hole technology (THT) remains the preferred solution for such components due to its superior mechanical strength and solder joint reliability.
Power On/Off Switch PCBA
Power Control PCBA
Power Interrupter PCBA
In April 2025, I.C.T successfully delivered a fully automated THT line to a major Hungarian manufacturer specialising in power switch systems. The complete line was installed and commissioned within one week by I.C.T engineer, Peter, who also trained the customer's team on operational best practices. This project exemplifies our ability to meet complex requirements with efficiency and technical excellence.
To meet the high standards of power switch manufacturers, I.C.T provides a fully automated, intelligent THT production line designed specifically to manage complex component profiles and challenging process steps. Below is an example of a customised solution developed for a customer producing large-scale power switch boards:
Take the actual production of high-power switch PCBA by the customer as an example: the overall product size is 370MM*196MM;
According to the product information and the actual process requirements, the following solution line is configured for the customer, taking into account the process difficulties and efficiency in production.
DIP process flow : component insertion → wave soldering → AOI inspection → online board separation
SMT PCB conveyor – PCB fixture loading
Odd-Form Component Insertion Machine – Accurate placement of non-standard components
PCB Conveyor – Seamless PCB transport
Wave Soldering System – High-efficiency soldering of inserted components
Wave Unloader – PCB unloading after soldering
Segmented Conveyor – Fixture separation
AOI (Automated Optical Inspection) – Real-time solder quality analysis
Reject Conveyor – Separates OK/NG boards
Inline Depaneling Machine – PCB panel separation
Module | Capacity |
Full Line Throughput | 64 units/hour |
Odd-Form Inserter capacity | 64 units/hour |
Wave Soldering capacity | 768 units/hour |
AOI capacity | 1,200 units/hour |
Inline Depaneling capacity | 310 units/hour |
Total power requirement: Max 38kW / Running power: ~10kW
Required footprint: Approx. 20m x 5m (100m2)
1 Engineer
3 Operators
1 Quality Control Inspector
Flexible staffing can be customized to specific production needs.
How to customized the THT Solution for Power Switch? Click here for free Solutions >>>
Video: Real THT Line in Power Switch Assembly:
1.The technology of THT automatic plug-in machine is mature.
2. The equipment intelligence and automation continue to develop, reducing a large number of manual operations.
3. Visual positioning system: Modern THT plug-in machines generally use high-precision CCD visual alignment to improve plug-in accuracy
4. AI-assisted optimization: Introduce AI algorithm to optimize the plug-in path and reduce empty plug-ins and wrong plug-ins
5. Special-shaped component plug-in: such as large electrolytic capacitors, connectors, transformers and other reliability components.
Power switch assemblies often involve non-standard parts and high thermal demands. Our solution addresses several common manufacturing difficulties:
1. Component adaptability difficulties. Non-standard components (such as large electrolytic capacitors, transformers, and non-standard connectors) have irregular shapes, are difficult to feed, and cannot be fixed by general fixtures.
Solution: Customized feeder supply according to components, such as vertical tape feeder, horizontal tape feeder, vibration plate feeder, etc., customized suction nozzles or mechanical grippers pick up components accurately and reliably.
2. Pin deformation leads to poor insertion.
Solution: Precision CCD identifies component pins, and the size of the plug-in before the plug-in is suitable for the plug-in after. In addition, the plug-in holes on the PCB board can be located twice to ensure the reliability of the plug-in.
3. PCB design compatibility issues, poor matching between through holes and components
Solution: Use DFM (manufacturability analysis) tools (such as Valor NPI) in the design stage
4. High-density PCB plug-in conflicts. In multi-layer boards or high-density boards, adjacent through holes are too close, resulting in mechanical interference
Solution: Optimize the plug-in sequence (AI path planning) and customize miniaturized plug-in heads.
5. The problem of inserting force control. Too much force will damage the PCB or components, and too little force will cause false insertion.
Solution: Servo motor + force sensor closed-loop control.
6. The problem of component floating during welding
Solution: The automatic plug-in machine adopts a bending foot mechanism to tighten the components, ensure welding reliability, and reduce the defective rate.
7. The wave soldering tin penetration is poor and cannot meet more than 75%.
Solution: The flux is adjusted evenly, double wave soldering is used, and the speed + expected setting of the best parameters.
8. Thermal shock causes PCB deformation, and the PCB warps after high-temperature welding, which affects the subsequent work.
Solution: Use synthetic stone fixtures to fix and protect the board and components.
In manufacturing power switch PCBA (Printed Circuit Board Assemblies), precision, consistency, and throughput are critical. With component dimensions reaching up to 370mm x 196mm and involving intricate soldering and testing steps, a fully automated THT line is not just an option—it is a necessity.
With over 25 years of industry expertise, I.C.T offers more than just equipment—we deliver peace of mind. Our global support network, European-standard CE-certified machines and customisable automation solutions make us the trusted partner for power switch manufacturers worldwide.
Ready to upgrade your power switch production with THT automation?
