Services
The Surface Mount section of Zeal’s Production process
utilises 2 fully automated pick and place machines. With a
dedicated team of trained operators a Mycronic MY300LX with
a 4K vision system provides the functionality of a system
capable of placing up to 18,000 components per hour with an
accuracy of placement accuracy of +/- 15um. This meets the
requirements for all components including 01005 passives and
the ultra-fine pitch/ BGA components.
Surface Mount Assembly
Zeal has two ScanSpection AOI systems at the end of their
surface mount line. These machines are programmed for
each individual assembly to allow the PCB’s to be inspected
for missing, incorrectly fitted or wrong value parts.
These machines can also be configured for mixed and
through hole technology assemblies and using the
comparator program they can compare an approved sample
with another assembly to highlight any differences between
the two.
Inspection
If you dont see a
service that you
require then please
contact us as we still
may be able to help.
There are still PCB assemblies requiring through hole
components, required for robust connectivity, high voltage,
certified products or legacy products.
Zeal can accomodate all through hole requirements and
mixed technology assemblies. We can also advise on
production processes to allow assembly to be more cost
effective.
Through Hole and General Assembly
Our services range from simple termination and connector
assembly, to the production of complex looms and specialist
cables.
We have a great deal of experience in the following areas :
Cable and Wire Assembly
The variety of work we carry out for customers often
displays cost benefits in supplying a comprehensive package
of assemblies and components, for use in our customers’
production line assembly or site installation.
By controlling the supply chain on behalf of our customers
we can offer a single source and control of component
delivery.
Procurement
In order to support our own manufacture of specialist,
engraved components, we have extensive computer
controlled engraving and plastic milling facilities.
In their simplest form we produce many identification labels
for the electronics and control industries, in engraved
plastic. Such identification systems may include cable ribbon
buckles or control panel nomenclature.
By incorporating our hot wire bending facilities we can also
produce complex shapes such as micro enclosures and
covers, cable management and bend control assemblies,
interface panels for connector bulkhead population.
In many cases the parts are highly customised for duty and
identification. In addition to standard typeface engraving,
special logos and artwork can easily be incorporated.
As per customer requirement we have a dedicated routing
machine which allows many proprietary enclosures to be
machined to customer specification. This removes the need
to outsource to another supplier which helps us control the
lead times and quality of the final product.
Engraving, Plastic Fabrication and Hot Wire Bending
We also provide an enclosure assembly service. We can
machine off the shelf enclosures to customer specification,
manufacture bespoke plastic enclosures or can assist in
having enclosures manufactured out of various materials.
Enclosure Builds
As required by some customers, we have the ability and
expertease to be able to encapsulate products as required.
Our dispensing equipment is setup to dispense a two part
mixture of the UR5051 compound in blue.
Encapsulation, Conformal Coating & Laquering
Further efficiency coupled with a built in redundancy factor
have been achieved through having a
secondary surface mount line able to
run independently or share the load of
any large or dual sided assemblies.
The pick and place machines are
augmented by a 10 zone reflow oven
achieving a fully controllable
temperature profile (KIC profile and
monitoring) for lead free and leaded
assemblies, two high performance
screen printers and a rework station facility with a x30
magnification to sustain the quality of the product. We also
have a BGA rework station with high definition cameras to
enable us to efficiently remove and replace any BGA devices.
We have a full range of Agilis feeders to a allow better pick
rates on all components. This allows the best yield out of any
materials either purchased by us or supplied by our
customers.
Click on the
photographs
for a larger
view…
We also assemble non-PCB assemblies such as battery packs
and other electro-mechanical assemblies.
We have expertise on bespoke assemblies serving the
specialist needs of very largecompanies and the needs of
SME's. Full flow soldering, cropping and test facilities, I/C
programming, support the assembly operations.
•
Preformed power, Alarm and control looms for enclosure
assembly in the telecommunication and Control
industries.
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Coaxial cable assembly and termination.
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Precision termination of “D” and miniature “D”
connectors, including PCB incorporation into back shells.
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Ribbon cable assemblies.
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Specialist balun manufacture.
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Assembly into cable interface frames.
The enclosures can be supplied unassembed, part or fully
assembled with connectors or cables as required. We can
also provide a label to your specification with serial
numbers, barcodes, qr codes and customer logo’s.
We also have experience with 19” rack and control panel
assemblies which we have assembled for the railway sector,
power stations and the food industry.
Such examples of procurement may include the supply of electronic assemblies,
their interconnecting cabling, power wiring, fusing, tooling, and all of the fixings
and consumables for final installation at site. Such practices can often save
significant installation time and guarantee quality for customers.
We also conformal coat and lacquer PCB’s and other items as
requested using various approved products and various
applications.
The machines are connected to our company network and a capture of each PCB
assembly is stored against the works order and unique serial number for full trace
ability.
The solderability of the PCB’s are checked using our high magnification inspection
equipment.
All cables and looms are fully tested and coded to our customer's requirements
and certified before shipment to their manufacturing or installation sites.
