S7000 Odd-Form Insertion Machine: Automating Switches, Connectors & Terminals in THT Assembly

Odd-form THT components — switches, connectors, terminals, eyelets and large pins — are the last holdout of manual labor in PCB assembly. They do not come in standard axial or radial tape, they need orientation and forming, and they are exactly where hand insertion creates the most scrap and rework. Southern Machinery's S-7000 series odd-form insertion machines automate this step with a published throughput of up to 12,000 CPH, vision-corrected placement and optional clinching — a direct answer for EMS, ODM and OEM factories that are still paying for manual insertion with quality and yield.

What is this machine used for?

What is the S7000 odd-form insertion machine used for?

The S7000 inserts non-standard, through-hole components that cannot run on standard axial or radial inserters: switches, connectors, terminals, eyelets, round pins and other odd-form parts with lead diameters of 1.3–4.0mm. It feeds, forms, inserts and — optionally — clinches leads automatically on PCBs up to 480mm × 390mm, with a single-head to four-head configuration to match your volume.

Which components can it handle?

Per Southern Machinery's published specification, the S7000 platform handles: 1.3–4.0mm Pin, Round Pin, Switch, Connector, Terminal and Eyelet. The series extends into dedicated variants — the S-7000T terminal insertion machine (reeled terminals such as Zierick P/N 1021/6021/1198/6198 and TE Connectivity TAB FASTON 6.35mm [.250in] or 4.75mm [.187in] at 5.08mm [0.2in] pitch), the S-7000D tact switch inserter for pushbuttons, and the S-7000I fuse holder inserter.

How fast is it?

The S7000/S-7000E platform specification lists 12,000 CPH. The S-7000T terminal variant is published at 5,000–6,000 CPH. Actual throughput depends on board design, component mix and head count — that is why Southern offers 1 to 4 insertion heads on the same machine.

Typical application scenarios

• Home appliance control boards — tact switches, fuse holders and connectors on air-conditioner, microwave, induction cooker and electric kettle PCBs, where high mix of small THT parts makes hand insertion a bottleneck.
• Automotive electronics — terminals, FASTON tabs and connectors for car audio and vehicle power supply boards; the S-7000T is set up for TE and Zierick reeled terminals with insertion verification.
• Power supply and ballast — connectors, pins and eyelets on vehicle power supplies, energy-saving power supplies and LED drivers.
• Industrial control and general electronics — digital watches, instruments and mixed THT assemblies where odd-form parts dominate the component count.

How the S7000 fits into a complete PCB assembly line

The S-7000 series is designed to sit inline between SMT and Wave Soldering. The PCB transfer mode is automatic (optional), the machine is loader/unloader-ready for Industry 4.0 integration, and the Windows-based industrial PC can connect to a MES system via RS-232C.

A typical line position:

1. SMT placement (Pick and Place) → Reflow Oven → SPI/AOI
2. S7000 odd-form insertion — switches, connectors, terminals and eyelets added after the SMT side is complete
3. Wave Soldering → lead trimming → cleaning → final AOI

For factories that buy the whole line, Southern Machinery acts as a single supplier: SMT, THT, Wave Soldering, board handling and inspection equipment are all part of its catalog, so the SMT/THT boundary — the most common source of integration friction — is handled by one partner.

The machine also works offline. Programming is Excel-based with USB data input, and the online visual programming mode lets operators teach insertion points with an industrial high-definition camera. That makes low-volume, high-mix changeovers practical without a network integration project.

Key selection parameters checklist

Before quoting a machine, confirm these parameters with Southern Machinery. Published platform values are listed where available:

• PCB size — max 480mm × 390mm (S7000); S-7000T standard 380mm × 280mm, enlarged size customizable.
• PCB thickness — 0.76–2.36mm.
• Component leads — 1.3–4.0mm diameter: pins, round pins, switches, connectors, terminals, eyelets.
• Insertion heads — 1 to 4 heads, optional.
• Insertion angle — 360° in 1° increments (S-7000T).
• Clinching — inward / outward / "N" (no clinch), optional; specify the clinch style your board requires.
• Programming — Windows-based software, Excel data import via USB, online visual programming, visual correction.
• Motion accuracy — 0.001mm/pulse with Panasonic controller and motors (S-7000T).
• Vision verification — industrial high-definition camera with automatic visual correction; insertion verification (S-7000T).
• Utilities — single phase 220VAC 50/60Hz (1.0KVA on S7000, 2KVA on S-7000T); air 0.4–0.6MPa (0.55–0.6MPa for round pins).
• Footprint — 2140mm × 1450mm × 1600mm (S7000); 1700mm × 1300mm × 1600mm for the 2-head S-7000T; weight approximately 1200kg.
• Integration — RS-232C for MES connection (S-7000T); loader/unloader and automatic PCB transfer options.

Buyer-side parameters to confirm: hole-to-lead ratio (published guidance: the insertion hole should be 0.5±0.1mm larger than the component foot), minimum body spacing (≥2mm between components), operating humidity (30–70%), and your required throughput in CPH to size the head count.

ROI, quality and capacity

Southern Machinery's published material sums up the problem the S-7000 solves: the biggest problems of manual insertion are low efficiency, poor quality, difficult processing, high defective rate and scrap rate, and high manufacturing costs. The S-7000 series addresses each one:

• Capacity — up to 12,000 CPH on the platform specification versus operator-dependent manual rates; the S-7000T terminal machine adds a published ROI of about one year for typical terminal-heavy boards.
• Quality — vision-corrected placement, insertion verification and insertion height control reduce bent leads and missing parts before they ever reach Wave Soldering; the S-7000T is published as passing the IPC-9704 stress-test standard, keeping the stress value of each insertion within ±400µε — important for automotive and industrial boards where cracked joints mean field failures.
• Clinching — inward or outward clinch locks leads mechanically before soldering, stabilizing the board for the wave and cutting rework.
• Scrap — controlled forming and insertion, plus visual correction, cut the defective and scrap rate that manual insertion produces on delicate odd-form parts.

FAQ

1. What is the S7000 odd-form insertion machine used for?

It automates the insertion of through-hole odd-form components — switches, connectors, terminals, eyelets and round pins — that standard axial or radial inserters cannot handle, with optional clinching and vision verification.

2. Which components can the S7000 insert?

Pins and round pins (1.3–4.0mm), switches, connectors, terminals and eyelets. Dedicated variants cover reeled terminals (S-7000T, including Zierick and TE FASTON tape terminals), tact switches (S-7000D) and fuse holders (S-7000I).

3. What PCB sizes does the S7000 accept?

Up to 480mm × 390mm on the S7000 platform, 0.76–2.36mm board thickness. The S-7000T standard is 380mm × 280mm with enlarged sizes customizable.

4. How is the S7000 programmed?

Windows-based software with Excel data import via USB, plus online visual programming using an industrial high-definition camera with automatic visual correction.

5. Can the S7000 be integrated into an existing SMT/THT line?

Yes. It supports automatic PCB transfer, loader/unloader integration for Industry 4.0, and RS-232C communication to connect to a MES system. It also runs offline for high-mix, low-volume batches.

6. What throughput can I expect?

The published platform speed is up to 12,000 CPH; the S-7000T terminal machine is specified at 5,000–6,000 CPH. Final throughput depends on component mix, head count (1–4) and board design.

Get a configuration recommendation

Southern Machinery (Shenzhen, China, founded 2011) designs and builds SMT/THT PCB assembly automation equipment and serves more than 237 customers worldwide — from EMS and ODM factories to appliance, power supply, automotive and LED lighting manufacturers. Ask for a configuration recommendation with the parameters above, or request a demo video of the S7000 odd-form insertion machine in action.

• Email: jasonwu@smthelp.com or info@smthelp.com
• Phone / WhatsApp: +86 13602562576 (Jason Wu, Sales & Service Engineer)
• Machine photo album: https://ph.smthelp.com
• Product catalogs, manuals and PDFs: https://file.autoinsertion.com
• S7000 odd-form insertion video: https://www.youtube.com/watch?v=QW8_1a19CkM