Delta Smart Press-Fit Machine Drives Efficiency For High-Mix Low-Volume IGBT Manufacturing

As global efforts accelerate toward higher energy efficiency and faster EV adoption, automotive electronics systems are evolving toward higher power, higher voltage, and lighter designs. As core components in EV inverters, power systems, and charging-converter modules, IGBTs must be smaller while offering high power density and robust thermal performance, making process stability and reliability critical.

Traditional soldering faces challenges such as thermal stress damage, high energy consumption, and defects like solder skips or voids that are difficult to detect visually, potentially compromising product stability. As a result, the industry is increasingly adopting Press-Fit technology as a solderless alternative. By mechanically pressing terminal pins into PCB holes, the method creates low-impedance and high-retention electrical connections through elastic deformation. Without soldering, heat-induced damage is avoided, and rework can be performed without desoldering, making it particularly suitable for high-value products.

Recently, Delta helped a leading EV-charging solution provider in northern Taiwan deploy the Manual Smart Press-Fit Machine DPF-M20 to improve their production of high-mix low-volume IGBT assembly lines. The company’s previous workflow relied on manual alignment and force adjustments, which resulted in inconsistent pressing force and speeds, as well as pin or PCB hole damage due to stress concentration. Additionally, variations in component height and pin length required repeated adjustments and validation during changeovers, limiting productivity. The lack of process data also made the traceability of anomalies more challenging.

Designed specifically for high-mix and quick-changeover production, the DPF-M20 leverages intelligent alignment, recipe management, and real-time monitoring to automate customers’ manufacturing know-how, transforming expertise into scalable processes. Furthermore, these features also make the DPF-M20 suitable for high-density, miniaturized, and high-value components such as AI server backplanes for HPC.

• Intelligent Alignment: Set transfer positions, sequences, and recipes in advance. After loading, the PCB is automatically transferred and aligned, and the system verifies the process order, enabling fast and repeatable operations for small-lot production.
• Recipe Auto-Match: Leverages smart algorithms with a comprehensive component database developed with parts suppliers to address tuning complexity caused by component variations. By entering specifications such as pin length, the system automatically selects the appropriate recipe without repeated trial-and-error.
• Real-Time Monitoring with Pre-Set Peak Values: Sets peak values for pressing force, speed, and slope based on customers’ own know-how, while simultaneously monitoring component conditions and incoming materials quality throughout the operation. Any anomaly triggers an immediate stop, preventing defects from entering downstream processes.
• Full Traceability: The DPF-M20 records up to 2,000 data points per second, capturing all key parameters to create a fully traceable production history and support process optimization.

Delta's Manual Smart Press-Fit Machine DPF-M20 offers the following benefits:

• Enhanced process reliability and yield - Intelligent alignment ensures precise control of pressing force, height, position, and sequence. Combined with real-time monitoring and peak-value pre-settings, the system detects anomalies as they occur, reducing rework and improving process stability and product yield.
• Enhanced high-mix productivity with lower energy and rework costs - Automated recipe matching, powered by a built-in component database, significantly shortens changeovers and validation time by quickly identifying the optimal recipe simply through inputs of specifications. The solder-free process reduces energy consumption, and rework can be performed without desoldering, which lowers material and operational costs.
• Real-time monitoring and comprehensive traceability - The system records work orders, serial numbers, and critical process data and can be integrated with MES platforms to provide full monitoring and traceability, ensuring greater control over production quality.

Delta's Manual Smart Press-Fit Machine DPF-M20 integrates intelligent alignment, automated recipe management, and real-time monitoring to reduce anomalies and rework, helping EV charger manufacturers overcome challenges in high-mix and frequent-changeover production. By capturing the complete process data and building a traceable production history, the system facilitates the conversion of operational know-how into standardized procedures, enhancing yield and reliability.