Configuring a THT Auto Insertion Line with Southern Machinery

Manual THT insertion is still common in power supplies, automotive electronics, industrial controls, LED drivers, and mixed SMT/THT products. The problem is simple: as volume grows, manual insertion becomes hard to control. Labor costs rise, quality depends too much on operator skill, and the THT area turns into a bottleneck behind the SMT line.

Southern Machinery builds cost-effective SMT and THT automation equipment from Shenzhen, China. Founded in 2011, we support over 237 global customers with PCB assembly automation solutions covering SMT, THT insertion, wave soldering, board handling, inspection, spare parts, training, and global service support.

This article is based on the local source page Southern Machinery | Automated THT PCB Insertion Line Solutions and explains how a complete THT auto insertion line can be configured for an EMS factory.

What Is This Machine Used For?

A THT auto insertion line automatically inserts leaded electronic components into PCB holes. Instead of operators manually placing axial parts, radial parts, terminals, connectors, or odd-form components one by one, the line uses dedicated insertion machines and PCB handling equipment to move boards through a controlled process.

In a typical Southern Machinery configuration, the line can include:

• PCB loader for automatic board feeding
• Axial insertion machine for axial leaded components
• Radial insertion machine for radial components
• Terminal insertion machine for terminal-type parts
• Odd-form insertion machine for irregular or larger components
• PCB unloader for automatic collection

The goal goes beyond speed. The real value is stable insertion position, controlled process flow, fewer manual handling errors, and a cleaner path into wave soldering or selective soldering.

Example THT Auto Insertion Line Flow

The source page shows a complete THT line flow:

1. PCB Loading - SLD250 Loader

Feeds boards automatically into the THT line. This reduces manual board handling and supports a more consistent line rhythm.

1. Axial Insertion - S4020A

Used for axial leaded components. The source page lists an example capability of up to 24,000 CPH, with 20 stations and 5–20 mm span. Treat this as a source-page example and confirm the final capacity based on your component type, PCB design, and machine configuration.

1. Radial Insertion - S3010A

Used for radial components. The source page lists up to 20,000 CPH, 10 stations, and 5–30 mm span. Final throughput depends on feeder setup, insertion program, board layout, and component condition.

1. Terminal Insertion - S7020T

Used for terminal-type components. The source page lists 0.6 s/point and intelligent insertion control. Final feasibility should be checked against terminal geometry, insertion force, PCB hole tolerance, and required tooling.

1. Odd-Form Insertion - S7900

Used for irregular components that don’t fit standard axial or radial insertion. The source page lists a vision system, dual-machine option, and 0.7 s/material as an example. For odd-form parts, the real engineering work is component presentation, gripper/nozzle design, and a stable insertion path.

1. PCB Unloading - SUL250 Unloader

Collects boards automatically after insertion, helping the line connect to downstream inspection, wave soldering, or buffer stations.

Typical Applications

A THT auto insertion line is useful when your product has repeated leaded components and production volume is too high for stable manual insertion.

Common applications include:

• Power supply boards with axial resistors, radial capacitors, terminals, and connectors
• LED driver boards with mixed SMT and through-hole parts
• Automotive electronic control boards requiring stable insertion quality
• Industrial control boards with connectors, relays, transformers, and terminal blocks
• Medical and telecom electronics where repeatability and process documentation matter
• High-mix EMS lines that need configurable insertion modules instead of manual labor alone

For example, a factory making power supply boards may use SMT for small passives and ICs, then move to THT insertion for capacitors, terminals, and connectors, then continue to wave soldering. In that case, the THT line must be balanced with the SMT output and the wave soldering process.

How It Connects to a Complete PCB Assembly Line

A practical full-line setup is usually:

SMT section: loader, automatic stencil printer, SPI if required, pick-and-place, reflow oven, post-reflow AOI, buffer or unloader.

THT section: PCB loader, axial insertion, radial insertion, terminal insertion, odd-form insertion, manual assist station (if some parts aren’t worth automating), and PCB unloader.

Soldering section: wave soldering or selective soldering, depending on PCB design, thermal mass, masking requirements, connector constraints, and product mix.

Inspection and traceability: visual inspection, THT AOI where justified, barcode scanning, process data collection, and MES connection if required.

Southern Machinery can help match the THT machines, wave soldering process, and board handling equipment as one integrated solution instead of treating each machine as a separate purchase.

Key Selection Parameters to Confirm

Before selecting the final line, confirm these points:

• Product type: power supply, LED driver, automotive electronics, industrial control, telecom, medical, or another product family
• PCB size range: the source page lists examples such as 50 × 50 mm up to 530 × 250 mm for loader/unloader, 50 × 50 mm up to 350 × 250 mm for axial/radial insertion, and 50 × 50 mm up to 550 × 450 mm for odd-form insertion
• Panelization: single board or panel, panel weight, and board support requirements
• Component mix: axial, radial, terminal, connector, odd-form, transformer, relay, heatsink, or other THT parts
• Lead pitch and body size: needed to confirm span, feeder, tooling, and insertion path
• Target output: boards per shift, working hours, shifts per day, and expected utilization
• Downstream process: wave soldering, selective soldering, or manual soldering for special components
• Quality target: IPC class, defect targets, inspection points, and whether insertion force monitoring is needed
• Automation level: fully automatic inline line, semi-automatic line with manual assist, or staged upgrade path
• Budget level: low, medium, or high investment range, including future expansion plans

ROI, Quality, and Capacity Value

The source page positions the line around reduced THT assembly cost, higher speed, improved accuracy, and more stable production. It mentions a cost-reduction message of 70% in the landing page hero. This should be treated as a marketing example, not a guaranteed ROI. Real payback depends on labor cost, shift pattern, current defect rate, component mix, downtime, and how many manual stations can realistically be replaced.

Where the line usually creates value:

• Labor reduction: fewer operators are needed for repetitive insertion work
• Stable quality: insertion position and process flow are more controlled than manual placement
• Higher throughput: axial and radial insertion machines can process repeated components faster than manual insertion when the product is suitable
• Better line balance: THT insertion can be connected with loaders, unloaders, buffers, and soldering equipment
• Scalable expansion: factories can start with the most painful component family and add more insertion modules later

A cheaper manual-heavy setup may be enough for prototype or very low-volume work. But for medium and high-volume EMS production, manual insertion often becomes the hidden bottleneck after SMT capacity improves.

Why Work With Southern Machinery?

Southern Machinery is a Shenzhen-based manufacturer founded in 2011. We focus on high-efficiency, cost-effective PCB assembly automation equipment for smart EMS factories.

Our scope covers:

• SMT lines and peripheral handling
• THT axial, radial, terminal, and odd-form insertion
• Wave soldering and selective soldering support
• Board handling: loaders, unloaders, conveyors, buffers, and inverters
• Inspection and traceability options
• Custom feeders, nozzles, grippers, and tooling
• Overseas installation guidance, remote support, spare parts, and operator training

For THT automation, the most important work isn’t just choosing a model name. It’s matching the machine type, feeder, tooling, PCB handling, soldering method, and inspection plan to your real product.

FAQ

1. Is a THT auto insertion line suitable for all through-hole components?

No. Some components are excellent candidates for automation, while others may still need manual assist or custom tooling. Axial and radial parts are usually easier to standardize. Odd-form parts require careful review of shape, lead design, packaging method, and insertion force.

2. Should I automate axial, radial, terminal, or odd-form insertion first?

Start with the component family that creates the biggest bottleneck: high volume, repeatable manual labor, frequent quality issues, or high operator fatigue. For many factories, axial or radial insertion gives the fastest first step. For connector-heavy products, terminal or odd-form automation may create more value.

3. Can the line connect to wave soldering?

Yes. A THT insertion line is commonly placed before wave soldering or selective soldering. The final setup depends on PCB design, component height, solder side clearance, masking, and thermal requirements.

4. Are the listed speeds guaranteed for every product?

No. The source page lists example values such as up to 24,000 CPH for axial insertion and up to 20,000 CPH for radial insertion. Final speed must be confirmed based on component packaging, PCB layout, feeder setup, insertion program, and acceptance testing.

5. What information is needed for a quote?

Please share product type, PCB size range, panelization, monthly or shift output, component photos or BOM, lead pitch, current process bottleneck, and whether you prefer a semi-automatic or fully automatic line.

6. Can Southern Machinery customize feeders and tooling?

Yes. Southern Machinery can support custom feeders, nozzles, grippers, and insertion tooling when standard handling isn’t enough. Final design depends on component samples and technical confirmation.

Next Step

If you’re planning a THT automation upgrade, send us four basic details: your product type, target output, PCB size, and the main THT components you want to automate. Southern Machinery can then suggest a practical line configuration from SMT to THT insertion, wave soldering, board handling, and inspection—without overspending on equipment you don’t need.