Tesla TECHNOLOGY

The PCB assembly takes place in two successive steps, SMT (Surface Mount Technology) and THT (Through-Hole Technology).

Surface Mount Technology (SMT) is the high-tech heart of any production. SMT components are mounted on two SMT production lines. The smaller of our production lines is equipped with the MY100 series of pick-and-place machines from the Swedish company Mycronic and is particularly ideal for mixed production of small and medium production batches.

The second more powerful SMT production line is designed for serial production. The basis of the line is the MYDATA MY300 series automatic pick-and-place machine. It is a machine with high-precision insertion heads with a maximum overall speed of 16,000 components per hour. Thanks to its excellent precision and high flexibility, this equipment enables continuous PCB assembly in large series. An automatic screen printing system for applying solder paste and adhesives, the Speedprint SP710, is included in front of this assembly machine.

The mounting of the THT components takes place on anti-static adjustable mounting tables. More than 20 workstations are equipped with a large number of forming machines and jigs for forming and cutting radial and axial electronic components. Machine soldering of mounted printed circuit boards is possible up to a width of 320 mm and a height of 80 mm. Manual soldering is carried out using ERSA i-con1 soldering stations.

Testing is an integral part of the quality production process. During production, our qualified staff performs extensive testing focused on the correctness of SMT and THT component fitting, soldering quality, and verification of the product in terms of meeting the prescribed parameters and its functionality. During testing we use the latest automatic 3D optical testers from SAKI. We have developed an extensive system of interconnected test fixtures and test equipment to control and evaluate the entire production process. We design and manufacture all these devices according to the product requirements and with respect to the customer's specifications and practices.

At the beginning was the product design and documentation. At the end of the manufacturing process is the final assembly including painting, gluing, and potting. We have all the necessary machinery in our company. The common goal of all these manufacturing operations is maximum protection of the components and printed circuit boards. The selection of the most suitable technology is always made with regard to the product and customer requirements.

In the 21st century, customers expect something more in addition to the timely delivery of a quality product. Quality, flexibility, and optimised processes are the norm and a must. True end-to-end partnership also includes the provision of data. Our testing platform has not only become the tool to perform all relevant tests, but also enables the creation and recording of large amounts of data. And of course we share this data with our customers.

The basis of our technology is the sputtering of thin films of precious metals on various types of substrates (Al₂O₃, SiO₂ etc.). A photolithographic process is used to create the required designs, followed by dry ion or wet chemical etching. For special applications we also use a trim laser, resistance welding machine, diamond saw, and screen printing of thick layers.

Specific sensing properties are achieved in thin film technology by combining thin layers of precious metals and sensing materials. Thin film technology excels in high precision and reproducibility, allowing us to produce sensors of very small dimensions with optimized properties such as high sensitivity, selectivity, and stability.

The wire wound resistor winding technology is designed to allow the widest possible use of wires made from suitable resistive alloys. We wind wires of various diameters from 0.02 mm to 5 mm with a precision of 0.01 mm. The wirewound method depends on the design of the required resistor. We offer three basic types of winding:

• winding on a cylindrical ceramic carrier with a precisely defined insulation gap and a maximum winding length of 650 mm.
• winding of self-supporting resistive spirals on an external metal rod; these spirals are then inserted into the ceramic body of the resistor
• winding on flat plates made of micanite or similar materials.

The wound wire shall be mechanically protected and insulated. The key element for the protection of the wire is a siloxane insulating sealant, which is applied by two basic technological processes. For cemented resistors, the technology of dipping followed by rotation is used to apply a uniform layer of sealant. In the case of aluminium housed resistors, silica sand backfill technology is used and then both sides of the resistor are filled with a waterproof cement-based grout with a degree of protection up to IP65 using a dosing agent.

In addition to resistors, TESLA also produces encapsulated and non-encapsulated current compensated and power toroidal chokes as well as chokes on cylindrical ferrite cores.

TESLA is the largest manufacturer of ignition cables in Europe. We use digitally controlled machines from ARTOS for cutting, stripping and crimping. Two fully automated production lines allow very flexible manufacturing from large batches to the production of small quantities. High flexibility is crucial for this product range. TESLA produces ignition cables under its own brand for the aftermarket, custom designs for OE projects, and cables under the private labels of its customers. 100% testing of all cables, constant testing and trialling of new materials, maximum variability in production, and the widest range on the market make TESLA what it is. The leader in ignition cables.

TESLA offers complete production technology for the assembly and manufacture of small cable harnesses. A large part of the production is focused on the production of cables for in-house projects in the electrical and automotive industry. The share of production for other customers requiring smaller and medium-sized production series with emphasis on flexibility and high quality is increasing very rapidly. Our offer includes mainly cutting and stripping of cables, wires and wire looms, tinning of wire ends, soldering and crimping of wires including the fitting of connectors, heat shrinking of looms, and subsequent assembly of smaller cable harnesses.

We focus on serial, small batch, and piece production of small mechanical parts for external customers, as well as parts for our own projects, especially in the electrical and electronics industries. We offer conventional, semi-automatic and automatic metal processing - turning, milling, grinding, drilling, cutting, wire cutting, threading, and countersinking. We also provide custom machining services in the form of design, fabrication, repair and maintenance of tools and instruments, including the assembly of smaller machine units.

NC lathe • NC milling center • Turning • External grinding • Internal grinding • Vertical external grinding • Vertical internal grinding • Milling • Flat grinding • Coordinate drilling and milling • Wire cutting • Countersinking