Customer scenario

A South Korean camera module OEM sought to upgrade from manual to semi‑automated welding for Voice Coil Motor (VCM) assemblies used in compact camera modules. The existing manual process limited throughput, introduced variability from operator-dependent electrode pressure and timing, and caused insulation damage or inconsistent joint strength on fine enameled wires (φ0.02–0.1 mm). The customer required a compact, bench‑friendly welder that could reliably replace imported thermal‑press units while boosting UPH to meet growing demand.

Challenges and root causes

• Low UPH and operator variability: Manual soldering/welding restricted hourly output and produced wide quality variance.
• Insulation breakthrough and false joints: Excessive or uneven electrode force during spot welding damaged enamel insulation, causing intermittent electrical failures.
• Inconsistent weld appearance and pull strength: Power supplies with slow feedback caused over‑ or under‑energy delivery, creating weak joints or burnt pads.
• Need for a domestic supplier: Korean VCM manufacturers preferred a local, cost‑effective alternative to foreign hot‑press welders to reduce lead times and support.

Mingseal DW200P solution

The DW200P micro spot welder was configured specifically for Korean VCM enameled‑wire applications, combining a micro‑force actuator and a high‑precision transistor power supply to address throughput and quality targets:

• Micro‑force actuator with controlled low pressure: The system’s actuator provides an adjustable force range with a minimum effective micro‑pressure of 40 g ± 5 g. This low, tightly controlled contact force prevents enamel insulation breakthrough while ensuring sufficient mechanical contact for energy transfer and repeatable weld formation.
• Fast transistor power supply with 10 μs real‑time feedback: The DW200P’s transistorized power module samples current every 10 microseconds and adjusts pulse energy in real time. This ultra‑fast feedback loop stabilizes instantaneous welding current and limits overshoot, producing consistent weld geometry and uniform pull strength across thousands of joints.
• Programmable pulse shaping and recipe storage: Operators can develop and lock optimized weld recipes for specific wire diameters (φ0.02–0.1 mm), pad geometries and substrate materials. Short pulse widths and tailored current profiles limit heat affected zones and reduce part deformation.
• Semi‑automated bench integration and vision alignment: The compact desktop frame (700×740×800 mm) fits bench or inline cells. Integrated vision guides accurate placement and reduces manual alignment errors, enabling reliable semi‑automated operation while keeping footprint and capital cost low.

Production outcomes and value

• Dramatic UPH improvement: By replacing manual welding with DW200P semi‑automation and optimized recipes, the customer achieved stable throughput of 1,800–2,000 welds per hour per station—meeting high‑volume module requirements.
• Higher first‑pass yield and reduced rework: Controlled micro‑pressure and rapid current feedback minimized enamel breakthrough and inconsistent joints, reducing electrical failures and rework rates.
• Consistent weld strength and appearance: Real‑time current control and pulse shaping produced uniform weld nuggets and repeatable pull strengths, improving downstream assembly reliability and cosmetic acceptance.
• Localized supply and support: As a domestic alternative to imported hot‑press welders, the DW200P lowered acquisition lead times, simplified spare parts sourcing, and enabled on‑site process tuning and faster technical support for Korean VCM shops.

Conclusion 

For Korean camera module manufacturers seeking to move from manual to semi‑automated VCM enameled‑wire welding, the DW200P provides a compact, high‑precision solution that raises UPH to 1,800–2,000 joints/hour while protecting enamel insulation and delivering consistent joint strength and appearance. Its micro‑force actuator and 10 μs transistor feedback loop specifically address the common failure modes of manual welding, making the DW200P an effective domestic replacement for foreign hot‑press systems. Contact Mingseal to pilot the DW200P on your VCM process and validate weld recipes for your wire sizes and module layouts.