**Abstract:**
An automatic single or dual wave soldering machine has been developed, utilizing a three-phase asynchronous induction pump as the crest generator, replacing traditional mechanical pump systems. This design eliminates rotating components, reducing wear and maintenance requirements, thereby significantly improving the reliability and efficiency of the entire system.
**Keywords:** three-phase asynchronous induction pump, wave soldering machine, maintenance-free, no moving parts
**1. Current Situation at Home and Abroad**
Dual-wave surface mount technology (SMT) involves the use of single-wave soldering processes for printed circuit boards. The application of liquid solder wave techniques and corresponding equipment is essential in this process.
In China, mechanical pump wave soldering machines have been widely used, with only a single-phase induction electromagnetic pump wave soldering machine developed initially. In contrast, abroad, most wave soldering machines still rely on mechanical pumps. In the late 1980s, Switzerland and the U.S. introduced conductive electromagnetic pump wave soldering machines (patent US-3.797.724), but due to unstable performance, they were eventually discontinued.
China made significant progress in the 1990s by developing the first generation of single-phase induction electromagnetic pump wave soldering machines (patents CN91058162A and CN93246899.3). Later, the second generation—based on three-phase asynchronous induction pumps—was successfully developed (patent CN96236223.9), leading to mass production of single/dual wave automatic soldering machines using this advanced technology.
**2. Necessity of Three-Phase Induction Pump Development**
Most current wave soldering machines in electronic assembly rely on mechanical pumps. These systems suffer from high-temperature rotation (around 250°C), leading to rapid wear, frequent maintenance, and contamination. Additionally, the rotation causes tin surface disturbances, increasing oxidation and slag formation, which raises production costs.
To address these issues, conductive electromagnetic pumps were introduced, eliminating rotating parts and reducing maintenance. However, their structural instability caused fluctuating wave peaks, making them unsuitable for certain applications.
In the 1990s, China developed a single-phase induction electromagnetic pump that solved some of these problems, offering stable wave performance without moving parts. However, it struggled with wide wave crests (300–400 mm) and ultra-high peaks (40 mm).
To overcome these limitations, the three-phase asynchronous induction pump was developed. It offers smooth wave crests, reduced oxidation, and the ability to produce wide and high peaks, meeting modern manufacturing needs effectively.
**3. Technical Principles**
**1. Mechanical Pump Soldering Machine Principle**
The mechanical pump uses rotating blades to push molten solder, resulting in wave instability. To stabilize the flow, additional pressure is required, which increases energy consumption and leads to more tin oxide slag. High-temperature rotation also causes blade wear and seal failure, requiring regular maintenance.
**2. Conductive Electromagnetic Pump Principle**
This system uses electromagnetic forces to move molten metal without physical contact. However, the direct conduction of current through electrodes can lead to oxide buildup, causing unstable wave peaks and limiting its effectiveness in high-demand applications.
**3. Inductive Electromagnetic Pump Principle**
This method uses magnetic phase differences to generate a forward force on the molten metal. While it improves stability, it still struggles with producing wide and high wave crests due to limited forward thrust.
**4. Three-Phase Asynchronous Induction Pump Principle**
This patented technology utilizes the inherent phase difference of three-phase power to create a stable forward magnetic field. This results in linear thrust, eliminating rotation and reducing wear. It produces smooth, stable wave crests, significantly reducing oxidation and slag, while allowing for high and wide peaks (up to 40 mm height and 400 mm width). It is highly efficient, with low thermal and electrical loads, ensuring long-term reliability and minimal maintenance.
**4. Application Effect Comparison**
Using a three-phase asynchronous induction pump-based wave soldering machine, several improvements were observed:
- The perturbation vibration wave superposition helps eliminate gas bubbles from flux decomposition, reducing defects like jump welding and shadow areas.
- Smooth wave crests result in less surface disturbance and oxidation.
- The system maintains peak stability even under voltage fluctuations, enhancing welding reliability and yield.
- High efficiency and low energy consumption make it ideal for continuous industrial use.
- No rotating parts mean no wear and no need for regular maintenance.
**5. Conclusion**
From the technical principles and practical application results, it is clear that the three-phase asynchronous induction pump-based wave soldering machine addresses most of the challenges faced by traditional systems. It offers maintenance-free operation, reduces solder waste and oxide slag, and enhances overall performance. With growing demand in SMT and electronic packaging technologies, this innovation is set to become a key player in the industry, offering strong international and domestic application potential.
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