Southern Machinery TO-90 90° Bend Radial Lead Auto Inserter for THT Assembly

What Is the TO-90 90° Bend Radial Lead Auto Inserter?

The Southern Machinery TO-90 is a bench-style THT (Through-Hole Technology) auto insertion machine purpose-built for radial components that require 90° lead bending prior to board insertion. These tall radial leads — commonly found in power inductors, transformers, large electrolytic capacitors, and discrete semiconductors — have historically demanded manual lead forming and insertion, a process that is labour-intensive, inconsistent, and a production bottleneck in high-mix EMS environments.

The TO-90 automates the full sequence: lead separation from tape/radial supplier packaging, 90° bend forming, insertion into plated-through holes, and lead clinching — in a single offline work cell that integrates into any THT or mixed SMT/THT assembly line.

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Typical Application Scenarios

Power Electronics Assembly

Power supplies, LED drivers, and vehicle electronics rely on through-hole inductors and capacitors with long radial leads. Manual forming and insertion of these components is a common cause of wrist fatigue and occupational injury. The TO-90 removes this manual step, enabling operators to supervise multiple insertion work cells simultaneously.

Energy-Saving Lighting PCBs

Industrial and street-lamp LED drivers use radial components with non-standard lead lengths. The TO-90's adjustable bend angle and insertion depth accommodate these variations without tooling changeovers, making it suitable for high-mix, lower-volume production runs common in lighting EMS contracts.

General Electronics EMS

Contract manufacturers running mixed SMT/THT boards — such as home appliance control boards (air conditioners, microwave ovens, induction cookers) — benefit from the TO-90 as a dedicated offline THT insertion cell that offloads radial components from SMT lines, freeing SMT placement equipment for surface-mount parts only.

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Integrating Into a PCB Assembly Line

The TO-90 operates as an offline insertion cell, meaning it does not require a full SMT production line to function. A typical integration workflow is:

1. Board fixturing: The operator loads the target PCB onto the TO-90's work holder.
2. Component loading: Radial components (e.g., from radial ammo-pack or tray) are loaded into the machine's feeder system.
3. Bend + Insert cycle: The TO-90 forms leads to 90° and inserts each component into the board.
4. Transfer to wave solder: The completed board moves to wave soldering for solder joint formation.

This offline approach means the TO-90 can run in parallel with SMT pick-and-place operations, reducing overall board assembly cycle time. Boards that require both SMT and THT insertion are first run through the SMT line, then routed to the TO-90 for radial component insertion before wave soldering.

Key integration considerations:

• Board size compatibility (verify PCB dimensions against machine work area)
• Lead diameter and component body height ranges supported
• Compatibility with your wave solder fixture height clearance

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Key Selection Criteria for THT Radial Insertion Equipment

When evaluating a radial auto inserter like the TO-90, EMS engineers and procurement managers should consider:

| Criterion | What to Verify |

|---|---|

| Component range | Radial component diameter, body height, and lead length that the machine can handle |

| Bend angle flexibility | Whether 90° (or other angles) can be set without mechanical retooling |

| Insertion speed | Components per hour (CPH) — verify against your production volume targets |

| Lead clinch quality | Clinch formation must meet IPC standards for through-hole solder fill |

| Board compatibility | Max PCB size and thickness the work holder accommodates |

| Feeder compatibility | Supports standard radial ammo-pack, tray, and stick-style packaging |

| Footprint and ergonomics | Does it fit your workshop layout and allow safe operator access? |

| Service and spare parts | Global support availability, lead time on wearing parts (feeder fingers, insertion pins) |

Note: Specific speed, accuracy, and certification data should be confirmed directly with Southern Machinery — all specifications must be verified against the machine's official datasheet before procurement decision.

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ROI and Quality Impact

Labour cost reduction: Replacing a manual radial insertion station (typically 1–2 operators per shift) with a single TO-90 work cell can yield significant labour savings in high-volume THT assembly. The machine runs continuously with one operator supervising multiple cells.

Repeatability and quality: Manual lead bending introduces dimensional variation that can cause insufficient solder fill or component tilt. The TO-90's mechanical lead-forming station produces consistent bend geometry batch-over-batch, reducing downstream solder defects and rework rates.

Throughput gains: For EMS factories producing power supplies or LED drivers with high THT component count per board, automated insertion substantially increases units-per-hour output compared with manual insertion.

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Frequently Asked Questions

What radial component types can the TO-90 handle?

The TO-90 handles radial components with long leads — including electrolytic capacitors, inductors, and transformers — that require a 90° bend before insertion. Component diameter, body height, and lead length specifications should be confirmed with Southern Machinery.

Is the TO-90 suitable for SMT/THT mixed boards?

Yes. The TO-90 is designed as an offline THT insertion cell. Boards that use both SMT and THT components typically go through SMT placement first, then the TO-90 for radial THT insertion before wave soldering.

How does the 90° bend process work?

Radial leads are drawn from the feeder, held in a forming station that bends each lead to the specified angle (e.g., 90°), and then the component is inserted into the plated-through hole on the PCB. The insertion head then clinches the leads on the solder side.

What are the service and support options?

Southern Machinery provides spare parts, sub-assembly repair kits, installation training, and equipment overhaul services from its Shenzhen headquarters. Contact Kevin Yang at kevin@smthelp.com or +86 13602562576 for technical and commercial inquiries.

Can the TO-90 handle boards of different sizes?

Board size compatibility depends on the work holder configuration. Verify that your target PCB dimensions fall within the machine's work area before purchase.

Does the TO-90 support lead-free soldering processes?

The TO-90 itself does not solder — it inserts components prior to wave soldering. It is fully compatible with lead-free wave soldering processes (SAC305, lead-free pastes) when used in a RoHS-compliant assembly line.

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Why Southern Machinery?

Southern Machinery (Smthelp) — founded in 2011, Shenzhen, China — is a precision SMT and THT PCB assembly automation specialist serving 237+ global clients across power electronics, LED lighting, vehicle electronics, home appliances, and general EMS manufacturing.

The company's equipment portfolio spans the full PCB assembly production chain:

• SMT placement and full production lines
• THT auto insertion (radial, axial, odd-form)
• Wave and selective soldering
• Board handling and conveyance
• Stencil printing and cleaning
• Smart factory and ESD storage solutions

Southern Machinery supports its global customer base with spare parts, on-site training, equipment upgrades, and repair services — backed by application engineers who understand EMS production workflows from quotation through to mass production.

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Ready to automate your THT radial insertion?

Contact Kevin Yang: kevin@smthelp.com | +86 13602562576

Learn more at www.smthelp.com

Product video: How to 90 bend Tall Radial Lead component Auto Insertion