Capacitor Lead Forming Machine S-EPCOS by Southern Machinery

What is this machine used for? The S-EPCOS is a custom bulk capacitor lead cutting and forming machine that takes loose EPCOS-style film capacitors from a vibration bowl, cuts both leads, forms 90-degree bends in X and Y plus a K-leg shape, and discharges finished parts at approximately 1,000 pcs/h. It is built to your capacitor drawing, with tooling confirmed before production by Southern Machinery, Shenzhen-based SMT/THT equipment maker since 2011.

Manual lead work looks cheap until inspection. Cut length drifts through the shift, angles vary by hand, and one mis-cut lead becomes scrap at insertion.

Why does manual capacitor lead work break down at volume?

For automotive, industrial, or power batches with thousands of bulk film capacitors, measuring and re-bending eats more time than assembly.

Hand-cut length drifts across shifts

Operators snip leads one capacitor at a time. Cut length varies by operator, by fatigue, and by tool wear. The source document for S-EPCOS lists this as the first bottleneck: consistent length is hard to hold by hand across a full shift.

Bend angles rarely match the drawing twice

The required form for the reference project is demanding: 2x R1.3, R0.8 max, 18.5 mm max, as-assembled to PCB. By hand, the 90-degree X/Y bend plus K-leg shifts part to part.

Throughput hits a staffing ceiling

Thousands of parts per day become a headcount problem. Hand work paces the THT line while insertion and wave soldering wait.

Manual work vs automated cutting and forming: what really changes?

The question buyers ask is simple: what do we gain if we move from benches to an 8-station indexer?

With S-EPCOS, the indexer disc positions every part, so the 10th part matches the 1,000th.

Consistency becomes mechanical, not personal

Fixed dies trim both leads. X, Y, K-leg, and reshape stations each do one job. Trimmings fall to a waste chute.

Bulk-in means no taping or trays

S-EPCOS accepts loose bulk capacitors directly. No tape or trays. One operator loads the bowl; a sensor confirms position.

One cabinet replaces several benches

Cabinet and control fit in approx. 1,800 x 1,200 x 1,900 mm, approx. 190 kg, on AC 220 V plus-minus 10%, 50 Hz. Air pressure must be confirmed by engineers.

How does S-EPCOS turn loose parts into 1,000 shaped parts per hour?

One part per cycle, eight stations, one rotation:

Stations 1 to 3: feed and position

01 Bowl loading: one operator feeds loose capacitors into the vibration bowl. 02 Vibration alignment: the track arranges parts into a single row, sensor confirms position. 03 Pick and place: the gripper takes each capacitor into the indexer with fixed positioning.

Stations 4 to 6: cut and bend in two axes

04 Lead cutting: upper and lower die trims both leads, scrap drops to the waste chute. 05 X 90-degree forming: first station bends leads 90 degrees in X. 06 Y 90-degree forming: second station bends 90 degrees in Y, plus front and back bending.

Stations 7 to 8: K-leg, reshape, discharge

07 K-leg and reshape: dedicated K-leg station, then secondary reshaping corrects spring-back. 08 Discharge: finished parts leave via conveyor into the collection box. Capacity is stated as approximately 1,000 pcs/h, depending on configuration and subject to final technical confirmation.

Typical uses: automotive, industrial control, power modules, and EMS lines inserting bulk film capacitors, from trials to mid-volume runs.

Where does S-EPCOS fit in your PCB assembly line?

S-EPCOS prepares parts for insertion and soldering. Place it before insertion and wave soldering so shaped capacitors drop cleanly into PCB holes.

A practical line position

Shaped output at 18.5 mm max speeds insertion and helps soldering yield. See blocks at www.smthelp.com and references at file.autoinsertion.com.

Key selection parameters at a glance

| Item | S-EPCOS value from source |

|---|---|

| Product model | S-EPCOS, custom bulk capacitor forming machine |

| Working stations | 8, indexer disc: cut, X 90 deg, Y 90 deg, K-leg, reshape, discharge |

| Capacity | Approx. 1,000 pcs/h, depending on configuration, subject to final technical confirmation |

| Input format | Bulk / loose EPCOS-style film capacitors, no tape required |

| Reference drawing | UE001UTT1A-01, Hanon / Magna, rev CN0000305, example from Visam project |

| Required lead form | As-assembled to PCB: 2x R1.3, R0.8 max, 18.5 mm max |

| Checked dimensions | Body length, body diameter, lead length against drawing |

| Power supply | AC 220 V plus-minus 10%, 50 Hz |

| Air supply | Listed as 5-7 MPa in agreement, likely a typo for 0.5-0.7 MPa, not specified in source, contact Southern Machinery to confirm |

| Dimensions | Approx. 1,800 x 1,200 x 1,900 mm LxWxH |

| Weight | Approx. 190 kg |

| Feeding | Manual bowl loading plus vibration track plus position sensor |

| Control | Integrated panel, vibration-speed regulator, sensor-confirmed cycles |

| Output | Collection conveyor plus receiving box |

| Position accuracy | Not specified in source, contact Southern Machinery to confirm |

Dies are drawing-specific; a different capacitor needs re-tooling.

What is the payback math?

Use this simple formula block for an example estimate only:

Monthly saving (example) = (rework hours saved x labor rate) + (scrap reduction x part cost) - machine operating cost
Payback months (example) = total investment / monthly saving

Example calculation, depending on configuration and subject to final technical confirmation: manual work with 3 operators at 3% rework versus S-EPCOS with 1 operator at an example 0.5% saves about 2 operators plus rework. No guaranteed ROI is offered.

Southern Machinery, founded in Shenzhen in 2011 and serving 237+ global customers, offers cost-effective SMT/THT automation with global service, spares, and training.

What checklist keeps forming quality stable month after month?

Use this weekly routine from the source:

Drawing-first discipline

Start from drawing plus sample plus annual volume, confirmed before tooling is cut.

Daily and weekly care points

Check bowl speed and sensors each shift, empty the waste chute, and verify first articles against 2x R1.3, R0.8 max, and 18.5 mm max.

Build a small sample library

Keep five good parts and two bad parts at the machine for instant comparison, photographed with the drawing number.

Next in this series: preparing shaped THT leads for higher wave-soldering first-pass yield.

FAQ

What capacitors can S-EPCOS process?

Bulk, loose EPCOS-style film capacitors. Input format is bulk with no tape required. The exact body range is tooled from your drawing, so send body length, diameter, and lead length for confirmation.

What lead shapes can it form?

Cutting plus 90-degree bends in X and Y plus K-leg forming and secondary reshape. The reference form is as-assembled to PCB at 2x R1.3, R0.8 max, 18.5 mm max. Other forms need re-tooling review.

What is the real throughput?

Approximately 1,000 pcs/h stated in the source, depending on configuration and subject to final technical confirmation. Final rate depends on capacitor size, lead form, and feeding stability.

What utilities and space are needed?

AC 220 V plus-minus 10%, 50 Hz, pneumatic supply, and about 1.8 x 1.2 m floor space at 1,900 mm high. Air pressure value in the agreement needs engineer confirmation before installation.

Can one machine handle multiple capacitor types?

Only with re-tooling. Cutting dies and forming tooling are drawing-specific. Tell engineers the new drawing and they will confirm what changes and what it costs.

How do I get a quote?

Email info@smthelp.com or WhatsApp +86 136 0256 2576 with your capacitor drawing, required lead form, and annual volume. The team replies with a tooling review and quote, typically within one working day per the source.

Send your capacitor drawing for a tooling review

If hand forming paces your line, send your drawing, sample, and annual volume to [info@smthelp.com](mailto:info@smthelp.com) or WhatsApp Jason. See www.smthelp.com.

Next in this series: how to prepare shaped THT leads for higher wave-soldering first-pass yield, with a readiness checklist you can use at incoming inspection.