Helping Shenzhen Enkor optimize its vertical component insertion process for speaker motherboards

Published On: February 9, 2024

1. Partner Overview

Client Name:: Shenzhen Enkor
Industry:: Multimedia audio, smart home, audio equipment
Application Products:: Speaker amplifier boards, power boards, control panels
Core Challenges:: High-density insertion of electrolytic capacitors and irregularly shaped components to improve the assembly consistency of speaker motherboards.

2. Project Background and Pain Points

Inconsistent Component Heights:

Speaker motherboards contain numerous electrolytic capacitors, transistors, LEDs, and touch springs. These components vary in height and shape, making manual insertion slow and prone to misalignment.
Compact PCB Space:

Modern speakers prioritize miniaturization, resulting in extremely small component spacing on the PCB. Manual insertion makes it difficult to ensure that surrounding components are not damaged.
Yield Bottleneck:

Audio equipment has extremely high noise control requirements. Poor soldering or improper insertion can lead to circuit noise, affecting sound quality evaluation.

3. Our Solution: High-Performance Radial Inserter

Tailor-made for Enco's product characteristics, we offer a high-performance radial inserter solution:

Multi-functional clamp design:

A specially developed gripper system simultaneously accommodates electrolytic capacitors of different diameters, TO-220 packaged transistors, and LED breathing lights.
360-degree rotating insertion head:

The insertion head can rotate in 1° increments, perfectly solving the problem of complex component layout angles on the motherboard and improving wiring density.
Secondary forming and lead locking technology:

The equipment automatically trims leads and locks them outwards/inwards after insertion, ensuring the components remain stable before wave soldering, significantly improving soldering quality.
Intelligent visual calibration:

Employing an independent standing visual recognition system, it automatically corrects PCB hole coordinates, addressing errors caused by board deformation.

4. Implementation Results

Evaluation Dimensions	Traditional Manual Line	Our Vertical Insertion Machine	Improvement Effect
Insertion Speed	600-900 pieces/hour	18,000-24,000 pieces/hour	Efficiency Increase of Approximately 20-30 Times
Insertion Qualification Rate	97.2%	99.95%	Almost Eliminates Rework Caused by Human Error
Labor Requirement	12 people (for the same production capacity)	1 person (only for material loading)	Saves Over 90% of Labor Costs
Product Consistency	Uneven Component Height/Angle	Fits Seamlessly, Highly Uniform	Improves the Reliability of End-Product Sound Quality

5. Customer Testimonial

"In the production of audio products, the stability of every component is related to sound quality. This vertical insertion machine not only solved our problem of high-density insertion, but also reduced the solder joint defect rate through a stable locking process, setting a benchmark for our automated factory construction."

— Production Supervisor, Enco Shenzhen

6. Choose our vertical insertion machine.

Supports mixed materials:

A single machine can simultaneously handle multiple spans (2.5mm / 3.5mm / 5.0mm / 10mm).
Easy maintenance:

Modular design, key components sourced from leading global brands, industry-leading mean time between failures (MTBF).
Fast delivery:

Strong supply chain capabilities ensure rapid response from order placement to on-site commissioning.