THT Auto Insertion Solutions: AI-6188, AI-6288 & AI-6488 Inserters by Southern Machinery

Manual through-hole component insertion is one of the last labor-heavy steps in a PCB assembly line. Southern Machinery's THT auto insertion solutions — built around the AI-6188 radial inserter, AI-6288 axial inserter and AI-6488 jumper wire inserter — replace repetitive manual work with servo-driven, PC-controlled automation that runs at up to 0.4 seconds per component.

What is this THT auto insertion solution used for?

This solution is used to automatically insert through-hole (THT) components — axial parts such as resistors and diodes, radial parts such as capacitors, LEDs and transistors, and jumper wires — into PCBs. Instead of operators hand-inserting each lead, the AI-series machines pick, position and insert components with consistent speed and accuracy, then the board continues to clinching, soldering or inspection. For EMS and ODM factories, that means fewer direct labor hours on the insertion stage, more stable output quality, and a production process that is easier to scale and trace.

The AI Series Product Line

Southern Machinery's THT auto insertion portfolio covers three core machine types, so you can automate the exact component mix on your boards:

AI-6288 Axial Component Inserter

Reliably inserts axial components such as resistors and diodes — the most common through-hole parts in power, industrial and automotive boards.

• Insertion speed: 0.4 s/piece
• Handles 40-160 component types
• Automatic PCB loading/unloading options

AI-6188 Radial Component Inserter

A versatile machine for radial components such as capacitors, LEDs and transistors, with high accuracy for dense boards.

• Insertion speed: 0.5 s/piece
• Handles 20-100 component types
• Precise servo-driven system

AI-6488 Jumper Wire Inserter

High-speed insertion of jumper wires to replace traditional manual processes, enhancing connectivity and structural integrity of PCBs.

• Insertion speed: 0.4 s/piece
• Supports various jumper spans
• PC control with a user-friendly interface

Typical Application Scenarios

• EMS and ODM production lines mixing SMT and THT boards where manual insertion is the bottleneck.
• Automotive electronics — connectors, relays, diodes and axial components with high repeatability requirements.
• Industrial control and power supplies — larger axial and radial parts that are difficult to feed by hand for eight hours a day.
• Medical electronics — where consistent insertion quality and traceability matter.
• Mixed-technology boards needing a flexible, modular THT cell that can switch between jumper wires, radial parts and axial parts.

How to Integrate into a Complete PCB Assembly Line

The solution is modular by design. You can start with a single AI-series machine for one component family, then expand to a full inline system as production needs grow.

• Before the inserter: SMT placement and reflow, or a PCB loader feeding boards into the THT stage.
• At the THT stage: one or more AI-series inserters for axial, radial and jumper wire components; optional automatic PCB loading/unloading keeps the cell running with minimal operator intervention.
• After the inserter: wave soldering fixes the inserted leads, followed by inspection and board handling for the next process.

Southern Machinery designs and builds the full line — SMT, THT, wave soldering, board handling and inspection — so the THT insertion cell can be specified, delivered and supported as part of one accountable system rather than a patchwork of suppliers.

Key Selection Parameters Checklist

When specifying an AI-series THT auto insertion solution, confirm these points with your engineering team:

• Component families on your board: axial, radial, jumper wire, or a mix
• Number of component types per machine (20-100 radial / 40-160 axial as a planning reference, depending on configuration)
• Required insertion cycle time (from 0.4-0.5 s/piece, depending on configuration and board layout)
• PCB size range and whether automatic loading/unloading is needed
• Board changeover frequency and setup workflow
• Existing line layout, conveyor height and connection to wave soldering
• Spare parts, training and service requirements for your site

ROI, Quality and Capacity Value

• Labor reduction: replacing manual insertion reduces operator headcount on the THT stage — the exact saving depends on your line configuration, shift structure and local labor cost.
• Quality stability: servo-driven, PC-controlled insertion removes hand-insertion variation, supporting consistent lead placement and fewer rework loops.
• Capacity: with insertion times of 0.4-0.5 s/piece (depending on configuration), a single cell can process thousands of components per shift without fatigue-driven slowdown.
• Line value: because the inserters integrate with loading, conveying, soldering and inspection, the whole THT segment can be planned as one automated flow instead of isolated workstations.

FAQ

What is this THT auto insertion solution used for?

It automatically inserts axial components (resistors, diodes), radial components (capacitors, LEDs, transistors) and jumper wires into PCBs, replacing manual through-hole insertion.

Which machines are in the AI series?

The AI-6288 axial component inserter, the AI-6188 radial component inserter, and the AI-6488 jumper wire inserter, plus flexible line configuration around them.

How fast are the inserters?

The AI-6288 and AI-6488 run at 0.4 s/piece and the AI-6188 at 0.5 s/piece, per the product documentation; actual throughput depends on your board layout and configuration.

How many component types can the machines handle?

The AI-6188 handles 20-100 component types and the AI-6288 handles 40-160 component types, depending on configuration.

Can the solution grow from a single machine to a full line?

Yes. The design is flexible and modular — start with one inserter and expand to a full inline THT system as production needs evolve.

Does the axial inserter support automatic PCB loading and unloading?

Automatic PCB loading/unloading is available as an option on the AI-6288, depending on configuration.

Get a Line Configuration Quote

Whether you are replacing a manual THT station or building a new mixed-technology line, Southern Machinery can help you scope the right AI-series configuration. Since 2011, the company has been designing and building SMT/THT PCB assembly automation equipment in Shenzhen, China, and serves more than 237 customers globally with high-efficiency, cost-effective equipment, global service, spare parts support and professional training.

Contact the Southern Machinery team with your board samples, component list and line layout for a personalized consultation and quote.

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Product specifications in this article follow the source product documentation. Final specifications, speeds and configuration options are subject to final technical confirmation with Southern Machinery.