LED HotBar Machine – A Lot of Different Recommendations for Getting a LED HotBar Machine.

We would like to provide you with a suitable technology for the efficient soldering procedure for our connection technology. Therefore we have now developed and implemented an extremely interesting solution. The Bar Soldering process connects different connection parts collectively. Simply because that the contact pads are usually soldered to some PCB it is important that materials used give a slightly different alloy, where reliable solder points can be accomplished. Ahead of the soldering process one of many two solder points is coated with flux and so the connector part is pressed onto this point through the still cold thermode. Subsequently a short heating from the hot bar soldering machine is carried out until the melting temperature is reached. The system is cooled down fast after the soldering has taken place. Air is almost always utilized for the cooling.


Although Hot Bar Soldering is a single solder process multiple solder connections are typically produced. One more great advantage may be the mechanical fixation of your solderable part through the thermode prior to the soldering process starts. As a result both parts can perfectly be used on the appropriate position.

Previous technique

Currents between 150 and 300 Ampere are used to heat the thermode. In classical systems the current is generated from a transformer. As a result of thick supply cables (thumb’s width) leading the actual towards the thermode these systems are nearly immobilized. They simply move a couple of millimeters toward the stroke which is sufficient to result in cable breaks – especially with the thermode connection – within a 24/7 operation.

Our technique

We use currents around 300 Ampere inside the thermode, nevertheless in our approach the thermode is put directly behind the energy electronics which converts the input current of circa 15 Ampere (input voltage 24V) around 300 Ampere. The 24 Volt supply line is thin as compared to the supply lines of conventional systems. Additionally the whole system is packed inside an aesthetic designer housing.


Throughout the soldering of Robotic Soldering Machine behave as in the foreseeable future application: They dissipate heat very well that makes it difficult to connect a part with one of these PCBs by soldering. The best solution with this dilemma is a Hot Bar soldering system because it applies enough energy to the solder points in order to develop a reliable connection in a limited time. Interesting applications

We provide the suitable connecting elements to keep sufficient high current flow.

Practical Example:

One application is the production of a daytime running light with higher power LEDs mounted onto an Aluminum core PCB and attached to one other. In this case the connection technology includes THT-jumpers with Hot Bar Soldering pads. The soldering was completed by Hot Bar Soldering process:


We present the center of our system, the Bar Soldering Generator BLG-300. Its design is different and is particularly only exceeded by its function.

Setup of your thermode

Normally the thermodes are constructed with stainless-steel, but in addition many other materials, e.g. Wolfram is feasible We deliver a broad variety of different widths so we often adapt the thermodes individually towards the customers soldering requirements. As a result of special thermode profile we achieve an extremely homogeneous heating. Integrated from the thermode there exists a temperature sensor positioned in many ways to create as near as is possible measurement results. As a result of complete pluggable connections the alteration of the thermode is indeed simple that you need about one minute. For series production we recommend buying two Hot Bar Soldering Generators to modify the thermode without time-related stress or production interruption.

Working cycle

On account of our special generator technique leading to a greater power in the Soldering Bar with the thermode and also the compatible control electronics our company offers a fast, high-performance system. Subsequently we chart a working cycle diagram because it is utilized to solder flex strips to a PCB. Dependant upon the application the cycle times may vary over time. By performing in house experiments and continuous parameter adjustment the perfect cycle times are achieved. Most of the time our systems work in three eight-hour shifts wherein a split second is essential. Thereby, it is essential to pick the cool off time – the time for cooling the solder bar before it really is lifted up from the soldering point.

Tabletop system BLS-50

Our Hot Bar Soldering system BLS-50 can be a complete system for direct utilization in the ongoing production. The New Bar Soldering station is dependant on a universal mounting within the base plate where various equipment can be applied. We could also construct and create the suitable mounting setup. In their simplest form you send us the parts which have to be soldered and that we construct the compatible mounting plate for yourself.

Together with the included control electronics all required parameters might be set. The apparatus is controlled using a two-button operation along with the whole device corresponds to the current CE safety standard. To implement the Soldering system a 380 Volt (16A) power source and compressed air (6-8 bar) is needed. The machine contains the tabletop as well as the associated power supply:

Upon request the Hot Bar Soldering station BLS-50 (model BLS-50-D)is offered that allows the pressure to become monitored electrically. In this instance, a precise control unit for 15dexopky with the prescribed target pressure values is provided. This special function is vital for all those processes where materials are soldered to very sensitive substrates in addition to monitoring and documenting all production parameters permanently. The control electronics that are included enables the setting in the following parameters:

Production line

In your affiliated company, NE-Sensoric GmbH & Co. KG, we build production lines matching perfectly to the Hot Bar Soldering system. Again, the focus is definitely on a universal possible application. The modular construction shortens the development and delivery time. By the use of industrial robots the Hot Bar Soldering system will be able to solve virtually every soldering task. Soldering in angular positions, offset rows and also different positions are no trouble for the system. If you wish to modify the LED HotBar Machine our recommendation is that you replace the total solder head since time required is less than a minute. This sort of system allows the customization to every single new production situation within your company.