Two odd form insertion machine solve 10 different THT components
Dual-machine THT automation strategy: configure odd-form inserters to handle multiple component types, reduce manual insertion work, and stabilize repeatability across mixed PCB assemblies.
Aug 2, 2026 · Updated Aug 2, 2026 · Southern Machinery
What Is the SOLVE-10 Dual-Machine THT Configuration?
The SOLVE-10 refers to a two-machine odd-form insertion configuration designed to handle 10 or more different THT component types within a single production line — without retooling between changeovers.
Rather than dedicating one machine to a single component family, the SOLVE-10 approach assigns component groups to two synchronized inserters, each optimized for different lead spans, body styles, or insertion forces. This parallel processing strategy is particularly effective for EMS manufacturers running high-mix, low-to-medium volume PCB assemblies.
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Typical Application Scenarios
Power Electronics and Power Supply PCBs
Power supply units (PSUs) for industrial equipment, LED drivers, and vehicle power supplies typically require multiple THT components — transformers, inductors, electrolytic capacitors, heat sink-mounted semiconductors, and connectors — each with different lead configurations. The SOLVE-10 dual-inserter configuration allows these components to be placed in a single pass, reducing work-in-progress (WIP) and eliminating manual insertion bottlenecks between assembly stages.
Appliance Control PCBs
Household appliances — air conditioners, washing machines, microwave ovens, induction cookers — rely on mixed THT component assemblies that change frequently with product generations. Running two odd-form inserters in tandem enables faster product changeovers while maintaining throughput on stable component families.
Automotive Electronics
Vehicle control modules, car audio systems, and dashboard electronics require consistent insertion quality across large production volumes. The SOLVE-10 configuration provides the repeatability needed for IATF 16949-aligned production while maintaining the flexibility to absorb engineering changes without retooling an entire line.
LED Lighting Drivers
LED driver PCBs often combine non-standard odd-form components — such as heavy inductors, bus bars, and large electrolytic capacitors — with standard radial components. Distributing these across two inserters prevents a single machine from being overloaded by high-mass or high-force components.
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Integrating Dual Odd-Form Inserters into a PCB Assembly Line
A dual-inserter THT cell typically sits downstream of the SMT placement line and upstream of wave soldering or selective soldering. The integration workflow:
- PCB arrives from SMT — already has surface-mount components placed and reflowed.
- THT insertion cell — dual odd-form inserters (SOLVE-10 configuration) place all through-hole components in one continuous pass.
- Lead clinching or flux dipping — ensures components are retained before soldering.
- Wave or selective soldering — completes the THT joint formation.
- Cleaning and inspection — post-solder residual flux removal and quality check.
Key integration considerations:
- Conveyor width and PCB rail spacing must accommodate the widest board in the product mix for both inserters.
- Component kitting must be planned around which inserter handles which component group — typically split by lead span, insertion force, or body dimensions.
- Nozzle and insertion finger calibration should be validated separately for each inserter's component set.
- Line balancing — the two inserters should be cycle-time-matched to avoid one machine creating a bottleneck for the other.
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Key Selection Criteria for Dual Odd-Form Insertion Systems
When evaluating a dual-machine THT configuration like SOLVE-10, engineers and procurement managers should assess:
Component Coverage
What lead spans and body styles can each inserter handle? SOLVE-10 configurations typically cover radial components from 2.5mm to 7.5mm lead span and odd-form components including transformers, relays, and heavy electrolytic capacitors. Verify that the machines can jointly cover your full BOM without gaps.
Combined Throughput
The effective line throughput is governed by the slower of the two machines. When specifying SOLVE-10, ensure both inserters are matched in cycle time for their respective component groups. A well-balanced dual configuration can approach 1,800–3,000 insertions per hour combined, depending on component types and PCB size.
Insertion Force and Lead Integrity
High-force insertion into heavy boards (power supplies, motor controls) risks lead bending or crack initiation. Look for machines with programmable insertion force control and lead clinching stations that secure components immediately after insertion.
Changeover Time
For high-mix production, changeover time between product families is critical. SOLVE-10 configurations that use quick-change nozzles and fixture-based PCB nesting can reduce changeover to under 15 minutes for most product swaps.
Board Size Flexibility
Confirm maximum PCB dimensions the dual configuration can handle. SOLVE-10 systems from Southern Machinery support boards up to 510mm × 460mm, accommodating most power supply and appliance control PCB sizes.
Spare Parts and Service
Given dual-machine dependencies, ensure the supplier maintains stock of insertion needles, nozzles, feeders, and vacuum pumps. Southern Machinery provides spare parts, on-site training, and remote support for SOLVE-10 configurations globally.
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ROI and Quality Benefits
Labor Cost Reduction
Manual THT insertion for complex, multi-component boards is a significant labor cost center. A dual odd-form insertion cell can replace 2–4 manual insertion stations, with the ROI typically recovered within 12–18 months for production volumes above 50,000 boards per year.
Insertion Repeatability
Automated insertion eliminates the variability inherent in manual operations — inconsistent lead seating depth, bent leads, and missed placements. This directly reduces solder defect rates (opens, insufficient fillets) and downstream rework costs.
Throughput Stability
Once the SOLVE-10 cell is balanced and calibrated, production throughput becomes predictable and schedulable. This enables accurate production planning and reduces overtime costs associated with manual insertion variability.
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Frequently Asked Questions
What types of components can the SOLVE-10 dual inserter handle?
The SOLVE-10 configuration covers radial components (capacitors, diodes, resistors with lead spans 2.5–7.5mm), axial components, and odd-form parts including transformers, relays, inductors, and connectors with non-standard body shapes.
How does SOLVE-10 compare to a single high-speed inserter?
A single inserter may handle more units per hour for a narrow component mix, but SOLVE-10 provides superior flexibility for mixed THT assemblies. When a board requires 10+ different component types, splitting across two machines reduces changeover time and prevents a single machine from becoming a bottleneck.
What is the typical changeover time between product families?
With quick-change nozzles and PCB nesting fixtures, changeover between product families typically takes 10–20 minutes for most configurations. Dedicated feeders for recurring component types can reduce this further.
Does Southern Machinery provide line integration support?
Yes. Southern Machinery offers on-site installation, calibration, and training services globally. Spare parts are stocked for rapid dispatch, and remote technical support is available for troubleshooting.
What are the service and spare parts lead times?
For standard spare parts (nozzles, insertion needles, vacuum pumps, feeders), Southern Machinery maintains inventory and can dispatch within 1–3 business days for most regions. Extended lead times apply for non-standard mechanical components.
How does SOLVE-10 handle heavy odd-form components like transformers?
Heavy odd-form components require high-force insertion heads and, in many cases, pre-formed or clinched leads to prevent movement during wave soldering. SOLVE-10 configurations typically dedicate one inserter to heavy components with enhanced insertion force capability and a secondary inserter for lighter radial/axial parts.
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Configure Your SOLVE-10 THT Insertion Cell
Whether you are building a new THT assembly line or upgrading manual insertion stations, Southern Machinery's SOLVE-10 dual odd-form insertion configuration provides the flexibility, throughput, and repeatability required for modern EMS production.
Contact Kevin Yang at kevin@smthelp.com or +86 13602562576 to discuss your component mix, board specifications, and production volume. Southern Machinery has served 237+ global clients since 2011, specializing in SMT/THT PCB assembly automation from their Shenzhen facility.
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