One-stop Smart Factory Solution for Smart TV Manufacturing

One-Stop Smart Factory Solution for Smart TV Motherboard Manufacturing

Smart TV Motherboard PCBA

For a PCB size of 230mm × 198mm, with approximately 500 components per board (2-panel configuration):

Smart TVs require highly complex and high-performance PCBs to ensure seamless functionality, including internet connectivity, AI-powered interfaces, and multi-device compatibility. As the industry transitions towards OLED, Mini LED, and Micro LED technologies, the demand for high-precision PCB manufacturing has significantly increased. A well-optimized SMT and DIP production line is essential to ensure the efficiency, quality, and reliability of TV PCBs in large-scale manufacturing.

Case Study: Comprehensive SMT & DIP Production Solution for Smart TV Manufacturing

SMT Production Line for Smart TV Manufacturing Configuration:

To meet the growing demand for high-quality TV PCBs, we offer a fully automated SMT production line designed for precision and efficiency. 

SMT Line for Smart TV

SMT Assembly Line for Smart TV

SMT line includes:

• Solder Paste Preparation & Printing:

• Solder Paste Mixer >>

• I.C.T-4034 Automatic Solder Paste Printer >>

• PCB Handling & Inspection:

• Automatic PCB Loader >>

• SMT PCB Conveyor & PCB Buffer Stations >>

• I.C.T-S400 3D SPI (Solder Paste Inspection) >>

• High-Speed Placement Machines:

• JUKI RS-1R High-Speed Pick and Place Machine (Dual Setup) >>

• Reflow Soldering & Post-Solder Inspection:

• I.C.T Lyra622N Reflow Oven >>

• AI-5146 Inline AOI for post-solder inspection >>

• Final Processing & Quality Control:

• PCB NG/OK Unloader >>

• I.C.T-5700L Routing PCB Separator >>

• BR-120 BGA Rework Station >>

• I.C.T-7900 X-ray Inspection Machine >>

• ICT-750 SMT Stencil Cleaner >>

• SMT Nozzle Cleaner >>

• Workforce Requirements:  Total: 4 personnel

• 1 Engineer

• 2 Insertion Operators

• 1 Quality Inspector

SMT Production Capacity & Efficiency

• Example: For a PCB size of 230mm × 198mm, with approximately 500 components per board (2-panel configuration):

• The SMT machine cycle time per large board: 150 seconds

• Production rate: 24 large boards per hour (48 PCBs)

• Energy consumption: 25KW/H, with factory gas consumption of 5-10m³/H

DIP Production Line for Smart TV Manufactureing Configuration:

For through-hole component mounting, our DIP production line provides a reliable solution for high-volume Smart TV PCB manufacturing:

DIP Line for Smart TV

DIP Assembly Line for Smart TV

• Assembly Line & Wave Soldering:

• 9-meter Plug-in Line >>

• Acrab350 Wave Soldering Machine >>

• Pre & Post-Wave Handling Units >>

• 6-meter Conveyor Line

• Workforce Requirements:  Total: 16 personnel

• 1 Engineer

• 9 Insertion Operators

• 3 Post-Wave Repair Technicians

• 3 Functional Testers

• 1 Quality Inspector

DIP Production Capacity & Efficiency

• Example: For a PCB size of 230mm × 198mm, with 24 through-hole components per board (2-panel configuration):

• Using fixture with 340mm × 280mm dimensions

• Wave soldering speed: 1200mm/min

• Production rate: 320 PCBs per hour

• Energy consumption: 7KW/H, with gas consumption of 3-5m³/H

Additional Processes for TV PCB Board Quality Assurance:

Beyond SMT and DIP assembly, additional steps are essential to ensure the highest quality standards:

ICT Testing:

● Initial inspection of solder joints and component integrity using in-circuit testers.

● Initial inspection of solder joints and component integrity using in-circuit testers.

● Customized test fixtures required for different product models.

Aging Test:

● Ensures long-term reliability of TV PCBs.

● Standard testing duration: 72 hours.

● Can be conducted using aging racks or simpler test setups.

With the rapid advancements in smart TV technology, an advanced SMT & DIP production line is crucial for manufacturing high-quality TV PCBs. Our one-stop smart factory solution provides end-to-end support, from PCB assembly machine and wave soldering to testing machine and quality assurance. 

By leveraging cutting-edge automation and stringent testing procedures, we help manufacturers achieve high production efficiency, reliability, and cost-effectiveness in smart TV motherboard manufacturing.

For more information about complete smart factory solutions, feel free to contact us.

I.C.T

Overall 0-1 SMT Machine Solution for Whole Factory

For you we can provide Full SMT & DIP & Coating Line Solution with best quality and service.

More information about I.C.T please Contact US or Email info@smt11.com