Industrial board repair - Page 1
Forum section: electronics / repair

author: tony359
author_rank: Frequent Contributor
timestamp: October 26, 2024, 09:11:08 pm
content: Hello,I don't know exactly where to ask this question, I hope someone could give me some pointers.Let's say I have many boards - hundreds or maybe thousands - where I need to replace about 100 components on them to make them work. I've been doing this myself, it takes some times but it works. Obviously I cannot do more than a few boards per month.Would there be a business somewhere on the globe which could do that for me in larger numbers? I'm thinking of some machinery which - once programmed - could quickly replace those 100 components in 30 seconds? Clearly that would have a high setup cost.Any pointers would be helpful!Thanks!Tony

author: CaptDon
author_rank: Super Contributor
timestamp: October 27, 2024, 01:23:19 am
content: Nope, you are looking at hand rework. Contract board manufacturers like Sunburst Electronics, 4front Solutions, Labarge in Tulsa or American Products Incorporated York Pa. can do that kind of work but it will be by hand and you won't like the price. What machine in existance can do what you need done? Desoldering specific parts and replacing? Are we talking SMD or through hole? Do you have all of the replacement parts and do they need processed like lead forming etc.?

author: Poroit
author_rank: Frequent Contributor
timestamp: October 27, 2024, 06:27:24 am
content: G'day tony359,As CaptDon points out , the style of components will have a large bearing on who could do them.Do you have Sheltered Workshops in UK that could handle the type of work you require?

author: tony359
author_rank: Frequent Contributor
timestamp: October 27, 2024, 10:16:32 pm
content: Thanks for your repliesThey're all SMD components.What is "sheltered Workshops"?QuoteWell, that's why I am asking

author: Poroit
author_rank: Frequent Contributor
timestamp: October 28, 2024, 06:01:51 am
content: G'day Tony,Sheltered Workshops are those where handicapped people (intellectually or physically) work part time on various tasks such as packing/recycling/basic soldering/assembly etc.The link below shows sites in OZ and you probably have similar in the UK.https://packforce.com.au/?gclid=EAIaIQobChMI56v7orGwiQMV3RaiAx1WxBHfEAAYASAAEgKmnvD_BwE

author: tony359
author_rank: Frequent Contributor
timestamp: October 28, 2024, 08:53:20 am
content: Thank you Poroit!

author: voltsandjolts
author_rank: Unknown
timestamp: October 28, 2024, 09:26:16 am
content: For that quantity of boards (you say hundreds or maybe thousands) and components that need replaced (hundred!) my first thought is to reverse the design and build completely new replacement PCBs. That may well be cheaper than manual rework, unless there are some high value parts on the assembly.Gotta ask, how on earth are there a hundred damaged components?!

author: Haenk
author_rank: Super Contributor
timestamp: October 28, 2024, 01:38:18 pm
content: And - or course - what kind of components are damaged? SMD electrolytic caps? Large ICs?For automated / semi-automated repair you might want to checkhttps://www.zevac.com/These machines do come with a pricetag of "really professional equipment" - but if you are repairing thousands of boards, they at least will help with larger parts. For SMD caps, these are probably not the right tool...

author: tony359
author_rank: Frequent Contributor
timestamp: October 29, 2024, 10:07:55 am
content: Quote from: voltsandjolts on October 28, 2024, 09:26:16 amIt happens when the marketing department is given the veto option on what engineering recommends!

author: Infraviolet
author_rank: Super Contributor
timestamp: October 29, 2024, 07:29:13 pm
content: It's only the removal part which is generally unsuitable for machines, is it not? So it might be feasible, assuming the components which need swapping aren't located in such a way that replacing them is semi-obstructed by components which remain in place unchanged, to remove manually and then clean up the pads so they're flat (no bulges of solder left), then use a pick and place machine to add the replacement parts on.

author: CaptDon
author_rank: Super Contributor
timestamp: October 30, 2024, 01:02:53 pm
content: Removing SMD parts and cleaning the pads is hand work. Then you have two options, 1. attempt to put solder paste on the pads (by hand) then pick and place (by machine) then run through a reflow oven to solder the new parts and pray you don't get tombstoning or damage to parts that were hand soldered in the original manufacturing process, or 2. Remove by hand the damaged components, install and solder the new components by hand. Will the newer 'better' replacement components fit on the original foot print or are they bigger / different. MLCC capacitors almost always become unreliable when hand soldered. The temperature gradient forced by the rapid rise in local heat as well as the quick cooling when the heat is removed causes physical and thermal stress and usually results in unpredictable failure modes of both infant mortality as well as long term instability. Not saying it can't be done. Our touch up / rework line was all women and they were VERY good at what they did when they understood what they were doing. I never had a 'touch up / rework' guy who could compare to the women!!