Insertion Line

Component insertion lines, also known as “electronic component insertion assembly lines,” are automated/semi-automated conveying and processing equipment specifically designed for the electronics manufacturing industry. They precisely insert electronic components—such as resistors, capacitors, diodes, transistors, and others—into the corresponding pad holes on printed circuit boards (PCBs). It serves as a core component of electronic assembly production lines (particularly THT through-hole technology lines), linking PCB cutting, component insertion, and subsequent soldering and inspection processes. This equipment directly impacts assembly efficiency, component placement accuracy, and the final quality of electronic products.

Core Functions and Application Scenarios of Insertion Lines

The core value of insertion lines lies in achieving orderly PCB board flow and efficient component insertion through standardized conveyor tracks and workstations. Their functions and applications are highly focused on the electronics manufacturing sector.

Core Functions

Precision Conveyance: Utilizes conveyance tracks (e.g., belts, chains, double-speed chains) to deliver PCBs smoothly and accurately to each placement station at preset intervals. This ensures stable board positioning for manual or automated component insertion.

Station Adaptation: Divides stations based on placement complexity (e.g., “Resistor/Capacitor Placement Station,” “Irregular Component Placement Station,” " Polarity Component Verification Station), enabling “one operator per station, dedicated placement for specific components” to enhance operational proficiency.

Auxiliary Positioning: Some placement lines feature PCB positioning fixtures (e.g., pneumatic stops, mechanical locating pins) to eliminate board misalignment during conveyance, ensuring precise alignment between component placement holes and pads (typically requiring ±0.1-0.3mm placement accuracy).

Cycle Time Control: Conveyor speed is regulated via variable-speed motors (typically adjustable between 0.5-5m/min) to match the insertion difficulty of different components (e.g., faster insertion for small surface-mount components, slower for large connectors), preventing congestion or delays between stations.

Typical Application Scenarios

Plug-in lines are primarily used in electronic manufacturing scenarios employing THT (Through-Hole Technology), particularly suited for assembling components with leads that require penetration through the PCB board—a task unachievable via SMT (Surface Mount Technology). Common application areas include:

Consumer Electronics: Main control boards and power supply boards for appliances such as televisions, washing machines, and air conditioners;

Industrial Electronics: Component insertion for inverters, PLCs (Programmable Logic Controllers), and industrial control motherboards;

Automotive Electronics: Plug-in processes for in-vehicle navigation systems, dashcams, and engine control units (ECUs);

Medical Electronics: Component assembly on internal PCBs of small medical devices (e.g., blood pressure monitors, blood glucose meters);

Communication Equipment: Mainboard plug-in components for routers and switches (e.g., non-standard connectors like Ethernet ports and power interfaces).

Main Categories and Characteristics of Plug-in Lines

Plug-in lines can be classified into various types based on dimensions such as automation level, conveying method, and layout configuration. Different types are suitable for varying production scales and process requirements.

By Degree of Automation

Manual Insertion Line Conveyor tracks

workstations, manual stop devices, component racks Simple structure, low cost (¥10,000–50,000 per line), high flexibility (rapid product changeover), easy maintenance Relies on manual skills,

relatively low efficiency (approx. 300–500 components per person-hour), insertion accuracy significantly affected by human factors Suitable for: Small-batch, multi-variety production; new product trial runs; complex irregular components (difficult to automate manual insertion)

Semi-automatic insertion line Building upon manual insertion lines

 incorporates “automatic feeders,” “component trimming machines,” and “automatic positioning fixtures” Reduces manual labor intensity (e.g., automatic component lead trimming), enhances insertion accuracy (mechanical positioning), and achieves 30%-50% higher efficiency than manual operations Core placement actions still require manual completion, with limited automation. Fixtures must be adjusted when switching products. Suitable for small-to-medium batch production; relatively fixed component types (e.g., large quantities of resistors, capacitors).

Fully Automated Insertion Line Automated conveyor system

 multi-axis insertion robot (or insertion machine), automatic feeding system, vision positioning system, defect detection mechanism Extremely high efficiency (approx. 1000-3000 components/hour), high insertion accuracy (±0.05-0.1mm), stable and reliable (unaffected by human fatigue), capable of 24-hour continuous operation High equipment cost (¥200,000–1,000,000 per line), complex debugging (requires reprogramming for product changeovers), high demands on component consistency Suitable for high-volume, single-variety production (e.g., mobile phone charger mainboards, power adapters); standardized components (resistors, capacitors, diodes, etc.)

Classification by Conveying Method

Belt-Type Insertion Line: Utilizes PVC belts as the conveying medium, characterized by low noise and smooth operation. Suitable for thin, lightweight PCBs (thickness ≤2mm) but with limited load capacity (≤1kg per PCB). Commonly used for inserting small-sized boards in consumer electronics.

Chain-type Insertion Line: Utilizes metal chains (e.g., roller chains) as the conveying medium. Offers high load capacity (≤5kg per PCB), excellent wear resistance, and extended service life. Suitable for heavy-duty PCBs (e.g., industrial control boards, automotive electronic mainboards). However, it generates significant operational noise and requires regular chain lubrication.

Double-Speed Chain Assembly Line: Utilizes a double-speed chain (where chain speed is asynchronous with the fixture carrier, typically 2-3 times faster), enabling “rapid PCB conveyance and precise positioning stops.” Suitable for scenarios requiring fast component transfer between stations with high precision, often integrated with automated insertion equipment.

Classification by Layout Configuration

Linear Assembly Line: The most fundamental layout, featuring straight tracks with workstations arranged along both sides. Its simple structure and compact footprint make it suitable for short-process assembly (e.g., PCBs with ≤50 components).

U-shaped insertion line: Features a “U”-shaped track layout where workers or equipment operate around the curve. Its advantage lies in minimizing material transport distance (end-to-end connection facilitates closed-loop PCB flow from “insertion start” to “soldering end”). Suitable for long-process insertion (high component count and multiple workstations), it enhances workshop space utilization.

Circular Insertion Line: Features a closed-loop track structure enabling continuous PCB processing through cyclic conveyance. Can integrate with multiple automated insertion machines to form “unmanned insertion cells,” suitable for high-volume, fully automated production scenarios. However, it requires substantial floor space and presents higher debugging complexity.

Development Trends in the Plug-in Line Industry

As the electronics manufacturing industry evolves toward “intelligent, lightweight, and high-density” production, plug-in lines are also undergoing

three major upgrade trends:

Integration of Automation and Intelligence: Manual lines are gradually being replaced by “semi-automated lines + localized automated equipment.” Fully automated lines incorporate AI vision inspection (e.g., real-time detection of component skew or missing placements) and integrate with MES (Manufacturing Execution Systems) to enable production data traceability (e.g., insertion time, operator, and equipment status for each PCB board).

Compatibility with SMT and THT Hybrid Processes: Traditional insertion lines only handled THT components. New-generation lines seamlessly integrate with SMT production lines, enabling hybrid assembly of “Surface Mount Technology (SMT) + Through-Hole Technology (THT)” components. This accommodates complex PCB processes like “one-side SMT placement and one-side THT insertion.”

Miniaturization and Flexibility: Addressing the characteristics of consumer electronics—rapid product iteration and significant batch size fluctuations—flexible insertion lines featuring quick-disassembly/assembly capabilities (e.g., modular tracks, rapid changeover fixtures) have emerged. Product changeover debugging time is reduced from hours to mere minutes, meeting the demands of high-mix, low-volume production.

In summary, as the “foundational backbone” equipment in electronics manufacturing, the selection and utilization of insertion lines directly impact production line efficiency and product quality. With advances in automation technology, insertion lines are evolving from “simple conveyance tools” into “intelligent assembly units,” becoming a crucial component in the intelligent upgrade of electronics manufacturing.