Complete THT Auto Insertion Line: Loader to Unloader by Southern Machinery

For EMS, ODM, automotive electronics, medical electronics and industrial control factories, manual through-hole insertion can become a costly bottleneck. Southern Machinery designs cost-effective THT auto insertion lines that move the board from automatic PCB loading through axial, radial, terminal and odd-form insertion to automatic unloading — one connected process instead of a row of manual stations.

What Is This Machine Used For?

A THT auto insertion line is used to automatically insert leaded (through-hole) components into a PCB — axial resistors and diodes, radial capacitors, LEDs and transistors, terminals, and odd-form parts — and then pass the finished board to soldering. Instead of operators placing each component by hand, the line feeds the board through a sequence of insertion machines that place components with high repeatability, vision guidance and controlled insertion force, so quality does not depend on shift fatigue or operator experience.

Why EMS Factories Automate THT Insertion

High Throughput

The line is designed to drastically increase production speed, with the S4020A axial inserter rated up to 24,000 CPH and the S3010A radial inserter up to 20,000 CPH in the source configuration (depending on board and component program).

Cost Reduction

Replacing manual insertion lowers labor cost per board and reduces material waste from mis-insertion. The source material positions the line to help reduce THT assembly costs by up to 70% — an example figure that depends on your current labor baseline, product mix and line configuration, and is subject to final technical confirmation.

Enhanced Quality

Vision-guided insertion and insertion-force monitoring deliver superior consistency and reliability, catching improper seating or bent leads before they become soldering defects.

Total Automation

The line is a complete, seamless process from PCB loading to unloading, so boards flow without operator handling between stations.

Typical Applications

The source documentation highlights consumer electronics, automotive electronics, industrial automation, aerospace, telecommunications and medical devices as primary beneficiaries. Typical component groups handled on the line include:

• Axial components — resistors and diodes, with the S4020A configured for 20 stations and 5–20 mm lead span
• Radial components — capacitors, LEDs and transistors, with the S3010A configured for 10 stations and 5–30 mm lead span
• Terminals — with the S7020T terminal inserter using intelligent insertion control at roughly 0.6 s per point
• Odd-form components — relays, connectors, transformers and other non-standard parts, with the S7900 vision system and optional dual-machine arrangement at roughly 0.7 s per material

Recommended Line Configuration: Loader to Unloader

The source line documentation specifies the following architecture:

| Machine | Model | Dimensions (mm) | PCB Size (mm) | Speed | Key Features |

|---|---|---|---|---|---|

| PCB Loader | SLD250 | 1150 x 750 x 1350 | 50x50 ~ 530x250 | N/A | Automated feeding |

| Axial Inserter | S4020A | 1750 x 1300 x 1600 | 50x50 ~ 350x250 | Up to 24,000 CPH | 20 stations, 5-20mm span |

| Radial Inserter | S3010A | 1750 x 1300 x 1600 | 50x50 ~ 350x250 | Up to 20,000 CPH | 10 stations, 5-30mm span |

| Terminal Inserter | S7020T | 1450 x 1300 x 1600 | 80x80 ~ 380x280 | 0.6s/point | Intelligent insertion control |

| Odd Form Inserter | S7900 | 3100 x 1300 x 1600 | 50x50 ~ 550x450 | 0.7s/material | Vision system, dual machines |

| PCB Unloader | SUL250 | 1550 x 750 x 1350 | 50x50 ~ 530x250 | N/A | Automated collection |

Specifications are reference values from the source product documentation and are subject to final technical confirmation for your specific configuration.

How to Integrate a THT Line Into Your Complete PCB Assembly Line

The THT section normally sits between the SMT side and soldering. In a typical flow:

1. Board input — the SLD250 loader feeds boards automatically after SMT reflow and inspection.
2. THT insertion — boards pass through axial, radial, terminal and odd-form insertion in the sequence your component mix requires.
3. Soldering handoff — inserted boards are handed to wave or selective soldering; the SUL250 unloader can collect finished boards for the next process.
4. Line integration — machines are selected and arranged around your PCB size, component span, throughput target and floor space, with loaders, unloaders and conveyors used to keep the flow continuous.

Southern Machinery can combine the THT section with SMT placement, wave soldering, board handling and inspection equipment into one complete line proposal, so you are not buying isolated machines but a connected production system.

Key Selection Parameters

Before requesting a quotation, prepare these details so Southern Machinery can size the line correctly:

• PCB size range, thickness and panelization (see the PCB size limits above)
• Component types and lead spans (axial, radial, terminal, odd-form)
• Throughput target in boards per hour or CPH
• Number of feeder stations required per machine
• Line-balance plan between axial, radial, terminal and odd-form insertion
• Whether you need automatic board loading/unloading and conveyor connection
• Vision, insertion-force monitoring and inspection requirements
• Floor space, power and air supply, plus spare parts and training needs

ROI, Quality and Capacity Value

The main value of a THT auto insertion line is structural, not just speed: fewer manual stations mean lower labor cost per board, vision-guided insertion and force monitoring mean fewer rework loops, and automatic board handling means fewer line stops. Depending on configuration, the source material positions a reduction in THT assembly cost of up to 70% as an example, with actual savings depending on your labor baseline, product mix and local cost structure, and subject to final technical confirmation. Southern Machinery's global service, spare parts support and professional training are designed to keep the line running once installed.

FAQ

What is THT automatic assembly?

THT automatic assembly automates the insertion of leaded components into a PCB. Southern Machinery's machines handle the entire process, increasing production speed, accuracy and efficiency while significantly reducing labor cost.

What are the benefits of using these machines?

Key benefits include drastically increased production speed, improved placement accuracy, reduced labor cost, enhanced product quality and reliability, and shorter project lead time.

Which industries benefit most?

The solutions are ideal for consumer electronics, automotive electronics, industrial automation, aerospace, telecommunications and medical devices.

How does insertion-force monitoring improve quality?

It ensures components are inserted with the correct force, preventing damage to the component or PCB. It detects issues such as improper seating or bent leads, improving overall assembly reliability.

Can the line be configured around my PCB size and component mix?

Yes. The architecture is modular — you can start with a single axial, radial, terminal or odd-form machine and expand to a full inline system as production needs evolve, with loaders and unloaders sized to your board dimensions.

What does a quotation from Southern Machinery include?

A line proposal normally covers machine selection, line layout, board-handling connection, specifications confirmation, spare parts support and professional training. Send your PCB size, component list, throughput target and current THT labor cost to start the configuration.

Get Your Line Configuration

Ready to automate your THT section? Contact Southern Machinery for a personalized consultation and quotation:

• Phone / WhatsApp: +86 136 0256 2576
• Email: info@SMThelp.com

Founded in Shenzhen, China in 2011, Southern Machinery has served 237+ global customers with SMT/THT PCB assembly automation equipment, including SMT placement, THT insertion, wave soldering, board handling and inspection — engineered for high efficiency, cost-effectiveness, global service, spare parts support and professional training.