Wire Soldering with a Wave - Page 1
Forum section: electronics / general

author: DLE
author_rank: Contributor
timestamp: September 25, 2023, 11:27:42 pm
content: Anyone ever used a wave to solder wires to a PCB? Have a project that requires 10 wires soldered per PCB a few hundred boards per month. I've looked at IDC terminals for direct wire to board. However, the cost on those is higher than I'd like. We will have a wave soon but have never seen anyone solder wires with a wave. Looking at DIP soldering as well but trying to limit the amount of equipment we need.

author: langwadt
author_rank: Super Contributor
timestamp: September 25, 2023, 11:40:38 pm
content: get this guy,https://youtu.be/HF0E8WeEUVM?si=sZFDAYm7T2c8PY9s&t=1381

author: DLE
author_rank: Contributor
timestamp: September 26, 2023, 12:11:50 pm
content: Ha no kidding

author: thm_w
author_rank: Super Contributor
timestamp: September 26, 2023, 09:53:07 pm
content: So this is a 10 pin ribbon cable or what?IDC terminals are dirt cheap, either you pay for that or the labor. I don't think there would be much difference between the two.https://www.ebay.ca/itm/171367180752Are there other TH parts on the board?

author: Doctorandus_P
author_rank: Super Contributor
timestamp: September 27, 2023, 09:23:43 am
content: Maybe it's worth to look into "selective soldering".It is a technique in which solder is pumped upwards though a tube like a little fountain.

author: DLE
author_rank: Contributor
timestamp: September 27, 2023, 02:21:41 pm
content: It's mostly 18awg wire and a couple 12awg wires. It's a legacy product we're taking over. Looking at a lot of options outside of soldering wires but just seeing if anyone ever has used a wave. I don't expect the wire insulation will hold up but thinking crazy thoughts to try .Selective might be an option, just hate the expense of that equipment.

author: ajb
author_rank: Super Contributor
timestamp: September 29, 2023, 02:28:52 pm
content: I've seen wires soldered to PCBs with little crimped terminals of some sort in between, particularly in PC PSUs where there are a whole bunch of ~18AWG wires landing on the PCB. I assume the terminals lock into the board somehow to hold the wire in place for wave soldering. If you have the equipment to do the crimping efficiently it seems like that would make the whole process easier.

author: mariush
author_rank: Super Contributor
timestamp: September 29, 2023, 02:46:01 pm
content: You could probably get someone to work part time and solder those boards manually... have him come in a Saturday, and pay him 1-2$ per board ... he'll do 20-30 boards an hour.. especially if you give him the wires crimped at the ends to just slide them easily in the holes. Crimping the wires ahead of time would definitely help speed things up... or at least a solder pot to pre-tin the wires.

author: langwadt
author_rank: Super Contributor
timestamp: September 29, 2023, 04:54:29 pm
content: Quote from: mariush on September 29, 2023, 02:46:01 pmyeh, unless fitting the wires can be automated there doesn't seem much point in automating the soldering

author: Matt-Brown
author_rank: Regular Contributor
timestamp: October 09, 2023, 05:43:05 pm
content: We have soldered wires to pcbs using wave. it depends on how long the wires are. We use a wave fixture and a hold downn for the wires