Helping Galanz overcome the bottleneck of automation of irregularly shaped components on microwave oven mainboards
Published On: July 14, 2025
Customer Name: Galanz Group
Industry: Microwave Oven Manufacturing, Smart Home Appliance
Application Products: Microwave Oven Control Boards, Electric Oven Power Boards
Core Challenges:
- Automated insertion of large-sized, irregularly shaped components such as relays, transformers, and heat sinks.
Galanz's microwave oven mainboard production line previously relied heavily on "manual insertion at the back end," facing the following difficulties:
- Heavy and complex components: Relays and current transformers are large and have thick pins, making them difficult for traditional insertion machines to grasp and accurately position.
- High insertion force requirements: Irregularly shaped component pins typically require significant penetration force to enter PCB holes; manual pressing can easily cause board deformation or finger injuries.
- High cycle time pressure: Galanz's single-line output is extremely high, and the speed of manual insertion of large components often becomes the bottleneck of the entire SMT/DIP production line.
Our customized odd-form inserter solution for Galanz represents a leap from "purely manual" to "fully automated":
- Flexible and Versatile Grip System: Utilizing a combination of replaceable vacuum nozzles and pneumatic grippers, a single machine can simultaneously handle relays, large inductors, heat sinks, and male/female sockets.
- Force Feedback Control Technology: Real-time monitoring of insertion pressure ensures that components are not damaged when entering the holes, automatically correcting even slight pin misalignment.
- High-Capacity Feeding System: Supports multiple feeding methods including vibratory feeders, tubes, and tapes to meet Galanz's diverse material specifications.
- Laser/CCD Hybrid Vision: 3D vision identifies minute deformations in component pins, ensuring a 100% insertion success rate.
After being put into use at Galanz's automated demonstration factory, the data feedback is as follows:
| Key Improvements | Traditional manual workstation | Irregular component insertion machine mode |
|---|---|---|
| Improved efficiency | Average throughput (UPH) 400-600 Pcs/h | 2,500-4,000 Pcs/h |
| Efficiency increase | 5-7 times | |
| Manpower savings | 5-6 insertion workers | 1 equipment operator |
| Labor cost reduction | 85% | |
| First pass rate (FPY) | 96% | 99.8% Extremely high quality consistency |
| Manufacturing cycle (L/T) | Long, affected by fluctuations in worker proficiency | 24-hour stable output Highly controllable production plan |
"Galanz is committed to building an 'unmanned workshop,' and the irregular component insertion machine is the final piece of the puzzle for us to achieve this goal. Your equipment maintained excellent stability under high-intensity operation, successfully solving our most difficult problem of large component assembly."
Our irregular component machine series is deeply optimized for the home appliance industry:
- Modular machine head: Supports 2-6 independent working heads, which can be flexibly configured according to capacity requirements.
- Easy Programming: Rapid import of CAD/Gerber data reduces line changeover and debugging time to less than 15 minutes.
- Excellent Compatibility: Capable of handling complex components weighing up to 50g and with a height of up to 35mm.
