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Induction soldering of electrical wires

Home/Induction Heating Applications/Soldering with Induction/Induction soldering of electrical wires
Induction soldering of electrical wires 2017-06-21T13:31:43+00:00

induction soldering of electrical wires

Objective
The customer needs to join two or more electrical wires for better electrical performance. Currently the customer normally twists the wires and adds hot melted tin to fill the gaps between the wires using resistive heating, but he would like to use induction heating for improving the quality and the speed of the process. The heating time should be less than 15s, otherwise the wire insulation will be damaged. Induction soldering allows finite process control and provides a consistent results.

Equipment
UPT-W15 Power Supply
HS-15SP Heat Station
UBraze Handheld Brazing System

Materials
• Twisted pairs of 10mm² and 25mm² cables
• SMD Solder paste (standard)
• Tin alloy

Test 1 (See Video 1)
2x 10 mm² multi-wires cables, standard solder for PCB

Key Parameters
Temperature: ~482°F (250°C)
Power: 1.5 kW
Time: 10-15 seconds
Frequency: 132 kHz

Test 2 (See Video 2)
2x 25 mm² multi-wires cables, SMD Solder paste (standard), standard solder.

Key Parameters
Temperature: ~482°F (250°C)
Power: 5 kW
Time: 10-15 seconds
Frequency: 134 kHz

Process:

1. SMD Solder paste is applied over the wires.
2. The operator placed the coil over the wires.
3. The UPT-W15 Power Supply is turned on to heat the wires in the coil.

After several tests, it was determined that 15 seconds is the ideal time to produce a good solder joint, while not overheating the insulation.

Results:

  • Strong durable joints
  • Selective and precise heat zone, resulting in less part distortion and joint stress
  • Less oxidation
  • Faster heating cycles
  • More consistent results and suitability for large volume production, without the need for batch processing
  • Clean and safe heat application, without pollutants

Pictures

Videos

Video 1

Video 2

Request information or contact us about this application. Reference info: Application Note 3464-4047

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