Main features
Fully Automatic Cutting Unit: Ensures precise cuts at the micrometer level and completely eliminates the risk of mechanical damage to delicate power components.
Programmable Voice-Coil bonding force system: Allows for a very wide and fine bonding force range from 0 to 1800 cN, optimizing bond quality for both large aluminum and copper wires.
Programmable automatic backstroke: Creates absolutely uniform wire bonding tails on all connections thanks to the synchronized coordination between the motor-driven Z and Y axes.
Mobile Wedge-Wedge bonding head for large wires: Increases flexibility in circuit design by supporting both front cut and back cut methods with a standard 2-inch long tool.
Synchronized hardware and software platform of the 53xx series: Minimizes training and maintenance costs for units with limited budgets thanks to standardized control structure and operating interface within the same ecosystem.
Store control parameters and wire loop shapes to hard drive: Shortens setup time when switching production batches by directly storing force, time, power configurations, and individual bond connections.
Detailed description
F&S Bondtec 5350 is a semi-automatic wire welding machine specialized for heavy wire processing applications. The device is designed to handle aluminum wire with a diameter of 100 to 500 µm on a 4-inch spool and copper wire with a diameter of 100 to 300 µm on a 4-inch spool.
The machine uses a Wedge-Wedge welding head for large wires, supporting both front cut or back cut methods. The standard tool length of the welding head is 2 inches.
The ultrasonic system of the device operates with the standard 58 kHz F&S Generator. The manufacturer also offers additional frequency range options including 40 kHz, 90 kHz, and 120 kHz depending on the bonding surface requirements. A key feature in the force generation mechanism of the 5350 is the Programmable Voice-Coil Bond Force System, which is programmable, allowing precise control of the bonding force range from 0 to 1800 cN.
In terms of kinematics, the machine features a multi-axis programmable control system, including a linear Z-axis with a travel of 60 mm and a linear Y-axis with a travel of 20 mm. Both axes are driven by stepper motors. The standard working height of the system is set at 55 mm. Fine adjustments in the X and Y directions are made through a mechanical manipulation arm system within a working area of 18 × 18 mm, equivalent to a geometric conversion ratio of 1:7.
Operational Challenges and Solutions
In a laboratory environment, sample fabrication, or microchip repair facilities, the biggest challenge when welding large power wires is the risk of mechanical damage to the delicate components located beneath the weld due to excessive wire cutting force, while also struggling to maintain the consistency of the welding wire tail.
The 5350 completely solves this problem by integrating a fully automatic wire cutting unit. This mechanism ensures that the wire cutting paths have perfect repeatability with micrometer-level accuracy without causing any risk of damage to the components.
In parallel, thanks to the combination of the Z-axis and the Y-axis driven by motors, it provides a programmable automatic step-back feature that creates identical wire tail sections on all joints.
Another issue for units with limited budgets is the training and maintenance costs when operating a large dedicated wire welding machine line. The 5350 addresses this by synchronizing the hardware and software platform similar to other fine wire welding machines in the 53xx family such as the 5310 and 5330.
The system uses a single-board computer running a step-by-step visual guide program (Coin-Guided Teach-In), allowing the storage of individual parameters and wire loop shapes onto the internal hard drive. The operating interface through a color display and a selection rotary wheel helps the operator master the equipment with minimal training time.
Integration and Expansion Capability
The hardware configuration of the 5350 comes with an integrated sample table heating controller that supports temperature control over a wide range from 0 to 250 °C.
The design of the welding head of the machine is almost identical to the welding heads of fully automatic welding systems from F&S Bondtec, ensuring high standard joint quality and facilitating easy upgrades to high-output production lines.
The manufacturer also offers an additional option for a wire feed spool equipped with a controlled motor to enhance stability for high wire tension.
The workholder system of the device is flexible for various component sizes:
Standard fixture: Designed for components up to 2 × 2 inches, integrating both vacuum suction to hold the sample and a sturdy mechanical clamp.
Optional fixture: Extend the workspace for larger components up to 4 × 4 inches with a mechanical clamping mechanism.
Optional 4 × 4 inch rubber-coated surface fixture: Integrates a non-slip rubber-coated surface combined with a dedicated mechanical clamping mechanism.