S-7020 Odd-Form Inserter Demo: Mixed-Component THT Insertion in One Program

Most THT lines still hand-insert odd-form parts because transformers, relays and connectors don't fit a standard radial or axial machine. That manual bench becomes the bottleneck between a fast SMT line and wave soldering, and quality drifts by shift. The S-7020 odd-form inserter closes that gap: in a recent demo it ran a mixed-component insertion sequence — several non-standard part types picked, oriented, inserted and clinched in one program.

The cost you haven't named: the odd-form island

Non-standard parts get pulled off the automated flow onto a bench nobody owns, and the whole line waits on it.

• The odd-form island. Parts that don't fit tape formats land on a manual bench, so throughput depends on hand labor and the bench becomes a hidden constraint on otherwise automated boards.
• Mixed boards break single-purpose machines. A board with transformers, relays, connectors and PIN terminals can't be done on one radial or axial head, forcing routing between separate stations and re-training operators per variant.
• Clinch quality varies by hand. Manual clinch angle and length drift shift to shift, which shows up as lifted leads and wave-solder defects after the board leaves the bench.
• One bottleneck between SMT and wave. The slow odd-form step caps the whole line's output even when SMT placement and wave soldering are both running fine.

The Four-Step Mixed Odd-Form Insertion Audit

Frame the demo as a repeatable way to qualify your own mixed board. Call it the Four-Step Mixed Odd-Form Insertion Audit.

1. List the odd-form BOM. Enumerate every non-standard through-hole part — transformers, relays, connectors, PIN eyelet terminals — and the terminal thickness (0.5–1.2 mm) and lead pattern each one needs.

2. Group by feed method. Sort parts into vibration-bowl or reel-fed groups, and confirm the insertion hole is 0.5 ± 0.1 mm larger than each lead so orientation and seating stay repeatable program to program.

3. Confirm the clinch requirement. Decide inward or outward clinch per part family, and set the program so every board locks components in place before wave soldering rather than relying on a manual squeeze.

4. Set the one-pass target. Define that the mixed board should clear all odd-form types in a single program and a single pass, with no manual re-routing between stations and no operator in the critical path.

The vehicle: S-7020 Odd-Form Inserter (capability demo)

The demo showed exactly how the audit maps onto the machine.

• List the odd-form BOM → dual-head mixed program. Two insertion heads run from one program, so a board carrying several different odd-form types completes in one pass instead of moving between manual stations.
• Group by feed method → bowl and reel feeding. Components feed from vibration bowl or reel feeders, covering bulk and reel-packaged terminals without a separate feeding cell bolted onto the line.
• Confirm the clinch requirement → selectable inward/outward clinch. The machine clinches leads underneath the board, mechanically locking each part so it stays put through wave soldering and reduces solder bridges.
• Set the one-pass target → 360° orientation and visual programming. With 360° rotation in 1° steps and online visual programming plus Excel data import, mixed boards change over quickly and every part seats at a fixed angle and depth.

Specification note: the rated 12,000 CPH, 380 × 280 mm board envelope, 0.5–1.2 mm terminal range, 360° orientation, 0.001 mm/pulse accuracy and utility figures are published reference values; exact performance is confirmed at quotation against your component mix and program.

Specifications

| Parameter | Value |

| --- | --- |

| Rated throughput | 12,000 CPH (2 heads) |

| Insertion heads | 2 (dual-head) |

| Standard PCB envelope | 380 × 280 mm (enlarged customizable) |

| Terminal thickness range | 0.5 mm to 1.2 mm |

| Hole-to-lead clearance | insertion hole 0.5 ± 0.1 mm larger than lead |

| Insertion orientation | 360° rotation in 1° increments |

| Clinch options | inward and outward, program-selectable |

| Motion accuracy | 0.001 mm/pulse; vertical error ≤ 0.8° |

| Power | 220 V AC single phase, 50/60 Hz, 2 kVA |

| Footprint / weight | 1700 × 1300 × 1600 mm; approx. 1,200 kg |

The loop: re-qualify every product revision

Odd-form work changes whenever a new board revision arrives. Build a loop: every product revision, repeat the Four-Step Mixed Odd-Form Insertion Audit, re-import the component data via Excel, and re-run a short demo sequence on the S-7020 to confirm clinch and orientation before ramping. Review the visual-program corrections with your process leads so drift is caught on the bench, not at wave soldering. The loop is what keeps a mixed-component program stable as the BOM evolves instead of drifting back to manual rework.

Your next step

Send us your odd-form component list and a sample board, and we will return a mixed-insertion program outline and a line-layout proposal showing how the S-7020 odd-form inserter fits with your SMT line, wave soldering and board handling. Reach Jason at jasonwu@smthelp.com or on WhatsApp +86 13602562576.

FAQ

What is an odd-form inserter?

It is an automatic machine that inserts through-hole components not fitting standard radial or axial tape formats — transformers, relays, connectors, PIN eyelet terminals and other non-standard parts — into a PCB before soldering.

What is mixed component insertion?

One machine program handles several different odd-form part types on the same board in a single sequence, instead of routing the board through separate manual or dedicated stations.

What components can the S-7020 insert?

The S-7020 Series PIN Eyelet Terminal Insertion Machine is designed for PIN eyelet terminals and other odd-form through-hole parts, with published support for terminal thickness 0.5–1.2 mm, fed from vibration bowl or reel feeders.

Does the S-7020 support clinching?

Yes. It performs inward or outward clinching, bending leads underneath the board so components are mechanically locked before wave soldering.

What is the published throughput of the S-7020?

The S-7020 is rated at 12,000 CPH with two insertion heads. Actual production throughput depends on your component mix, board layout and program.

Jason Wu

Founder & CEO, Southern Machinery (Shenzhen Southern Machinery Sales and Service Co., Ltd.)

Email: jasonwu@smthelp.com / info@smthelp.com

WhatsApp: +86 13602562576

Catalog & manuals: file.autoinsertion.com | Machine photos: ph.smthelp.com

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