Ersa i-CON Trace

The connectivity of the i-CON TRACE brings manual soldering up to a new level. It makes the process transparent, traceable and allows documentation of each individual soldering process. The PCB, the component to be processed, the soldering tip used, the process temperature and soldering time are recorded electronically and can be traced – for your own documentation and as proof for customers. Certain tasks which were previously not possible or could only be reworked mechanically can now be processed manually without risk.

Connection to an MES (Manufacturing Execution System) also permits the integration and saving of the soldering parameters used in complex, networked manufacturing processes which already run via an MES. Thus it is already possible to download a recording of the entire soldering task via a desired file format and save this in a higher-level control system. For real-time communication between the soldering stations in production and the customer’s MES, Ersa offers the possibility of a customised solution by means of a gateway.

Another important factor is the possibility to centrally pre-set all essential parameters of the soldering process with regard to the respective soldering task by qualified personnel. Thus, for example, a customer-specific soldering task can be created for a certain sensitive component and the respective parameters can be predefined. As soon as this component has to be processed, the corresponding soldering task is assigned and the soldering specialist can only start work when all the parameters for this corresponding component have been selected and set. This significantly increases process reliability. The operator can concentrate entirely on soldering – the susceptibility to errors decreases. Any malfunctions e.g. soldering temperature outside the process window, defective heating element, wrong soldering tip in relation to the component, are detected and displayed by the system.

Device management is also made so much easier by the server-based software concept. Firmware updates, calibration intervals, in future even soldering tip wear – everything can be monitored and individually traced. Since every mobile device in the network can communicate with every soldering station in the network, firmware updates are child’s play. The firmware of each individual station can be updated with just a few clicks via a PC in the office of the production manager. A similar scenario arises for the regular calibration intervals e.g. every two years. In many cases, the individual soldering stations are calibrated at different times of the year. The calibration intervals are stored in the software and can also be viewed for all soldering stations in a production area via a central PC and even be provided with a reminder function.

The second essential feature is the operating concept of the i-CON TRACE. With only one on/off switch and three LEDs, the interface of the soldering station differs significantly from all other industrial soldering stations with their complex setting options and a display. Due to the fact that the software is centrally located on a customer server and not on each individual PC, access and operation is quick, easy and demand-oriented via any mobile end device.

Via a mobile app for smartphones and tablets, the i-CON TRACE can be used like a conventional stand-alone soldering station even without a connection to a company network. The program for controlling the soldering station runs on the mobile end device – relevant information such as set and actual temperature is displayed on a smart device via Bluetooth or WLAN and can also be changed there. This enables demand-oriented, smart operation for the user.

The i-CON TRACE sets new standards with new features not only with regard to connectivity and a new operating concept – Ersa has also broken new ground in terms of hardware in order to raise technologies that have proven themselves thousandfold to a new level. For example, both the heating element and the soldering tip of the i-CON TRACE can still be changed separately from one another without any loss of soldering performance. With a maximum of 150 W, the soldering iron provides enormous power, and the soldering tips, which have been redesigned from the scratch, deliver this power precisely to where it is needed – to the solder joint. The fact that the soldering tips can be changed independently of the heating element means that each wearing part only needs to be replaced when it is really necessary. This significantly reduces costs over the entire life cycle of the soldering station and additionally saves material and resources. The i-CON TRACE is therefore not only an economical but also an ecological benefit for all electronics manufacturing.

In order to always have the right soldering tip on hand for the various soldering applications, Ersa offers a variety of different shapes and sizes of soldering tips. Even customised tip shapes for special applications are no problem. Tip´n´Turn is the patented concept for joining heating element and soldering tip, which enables tip change in record time. Each tip has a bayonet lock which, in combination with the multifunctional holder, allows particularly fast and safe changing of the soldering tip. The soldering iron including tip only has to be placed in one of the openings provided and turned through approx. 10° – the old soldering tip can then be removed and a new, suitable tip can be fitted. This can be done by hand, even without the storage stand. Even while hot.

With the i-CON TRACE as “The Missing Link”, the gap in terms of Industry 4.0 and traceability in electronics production is finally closed – and in the future allows complete traceability for the hand soldering process as well. With its unique software concept and the intuitive and smart user interface, the manual soldering process is safer than ever before. Together with the enormous power and the low operating costs, the Ersa i-CON TRACE takes your manual soldering process to a new level. See for yourself and get to know the i-CON TRACE at the Productronica 2021!

Conserve resources through rework:
With a high level of control over the manual soldering process, even PCBs that have defective solder joints after mechanical soldering and need to be reworked using a soldering iron can be reused.

Targeted root cause analysis:
On the one hand, the “tracing” of electronic assemblies simplifies the analysis of potential problems even before the product is delivered. On the other, it is possible to determine the extent of the problem and isolate its cause if assemblies are returned.

Continual improvement:
Traceability provides information that contributes to a lean manufacturing process, minimises waste and promotes improvements in series production.