The PININSERT 2100 XL by SM Contact is a high-performance CNC semi-automatic pin insertion machine designed for fast, accurate, and reliable insertion of connector pins into printed circuit boards (PCBs). Developed for high-volume production, the machine combines programmable CNC control with flexible configuration options to deliver consistent insertion quality and increased manufacturing efficiency.
Designed for manufacturers in power electronics, automotive, industrial automation, electric motors, and renewable energy, the PININSERT 2100 XL helps automate one of the most critical stages of PCB assembly while reducing labor costs and improving process stability.
High-Speed CNC Pin Insertion
The PININSERT 2100 XL is capable of inserting up to 8,000 pins per hour with a single insertion head, 16,000 pins per hour with two heads, and up to 32,000 pins per hour using four insertion heads. This scalable configuration allows manufacturers to increase production capacity without compromising precision or repeatability.
With a typical cycle time of just 500 ms per pin, the machine delivers high productivity for demanding production environments.
Technical characteristics
| Power supply | 220 V. 50 Hz single-phase 10 A |
| Power | 2,0 kW |
| Instantaneous cycle time | 500 ms/pin |
| Max pin’s length (standard version) | 25 mm |
| Max pin’s length (long version) | 60 mm |
| Max pin’s cross section | 1.5 mm |
| Time of head insertion change | 10 min. |
| Time of set of part change into insertion head | 15 min. |
| Standard motorized X axis (option) | 400 mm stroke |
| Standard motorized Y axis (option) | 400 mm stroke |
| Weight (basic) | ? kg |
| Dimensions (W x D x H) | 1200 x 1200 x 1600 mm |
| CE conformity | ✓ |
Pins unreeling systems
There are various pin feeding systems according to each pin type: end-to-end pins floor-mount unreeler, carrier pins unreeler for bandolier pins, terminal unreeler.
Universal table for PCB
400 x 400 mm universal table includes movable clamps to fix PCB plates of various dimensions and 10/20 mm stroke anvil to support PCB at insertion point. Thanks to it there is no need to change fixture when changing to new application.
Y table for plastic connectors
Y table allows to load special removable fixture for plastic connectors. Fixtures have centering finger for correct positioning and can be equipped with alignment supports that will fix each connector.
Using two fixtures speeds up the process: while one is operated, operator loads the components to the second one.
Electrical insertion head
Electrical insertion head is fully interchangeable which simplifies change to the new application. There are several types of insertion heads according to the pin types: end-to-end, right angle, U-band (bandolier) or terminals. Insertion accuracy is highly stable and equals ±0,05 mm (CPK > 1,68).
Insertion depth is controlled by encoder and can be programmed to one-hundredth of a millimeter in the PC editor whereas equipment of other brands should be mechanically set. Thus there is no need in mechanical adjustment for each new series.
Insertion technique involves the use of precut round or square wire with acceptable section from 0,3 to 1,5 mm (with servo-drive head) or 1 mm (with pneumatic head).
Indexation system
The pin is fixed in the insertion head one step before cutting position, which decreases the tolerance of pin length and thus provides cutting and insertion precision.
Easy-to-operate PC interface with standard PC keyboard & mouse
Lighting & safety beams
Safety beams can be installed on the frame to detect foreign object presence and to stop the machine. This feature as well as work area lighting guarantees operator’s safety.
Automatic components loading/unloading
Electrical belt conveyor to load and unload components to/from Pininsert set in line with other equipment.
Insertion height camera control
Low/high definition camera with integrated logics for pin height insertion control.
Components position laser control
Components position laser control detects wrong positioning, sends an error message on the screen and doesn’t let the machine work till the component is placed correctly
Insertion camera control
Special camera determines the position of 3 extreme holes in the PCB and, on this basis, calculates the position of all the holes and insertion points correspondingly.
Pin presence laser control
Pin presence laser control lets the machine differ empty slots and already inserted pins. New pins are inserted into the empty slots only and other positions are skipped.
Insertion force control
System controls each insertion and compares it to the reference values of insertion force. In case of deviation machine stops automatically or gives an alarm sound.
Force data export to Excel
System allows to download all the insertion data in Excel format.
Poka Yoke
Parts indicated by laser or insertion force sensor as defective are to be thrown into special container. Until these parts are detected inside of the container, the machine wouldn’t continue operation.
Barcode reader
Flexible Production Solution
The machine is fully controlled by an industrial PC and features a programmable insertion height, allowing quick adaptation to different PCB designs and connector types.
The PININSERT 2100 XL can operate as:
- A stand-alone production unit
- Part of a fully automated production line
- A flexible manufacturing cell for various PCB assemblies
Its modular architecture makes it suitable for both medium- and high-volume production.
Precision and Repeatability
Accurate pin positioning is essential for reliable electrical connections. The CNC-controlled motion system ensures every pin is inserted with exceptional precision, minimizing insertion errors and improving overall product quality.
The machine supports connector pins with a maximum cross-section of 1.5 × 1.5 mm and pin lengths of up to 35 mm (standard configuration), making it suitable for a wide range of applications.
Fast Changeover for Maximum Productivity
The PININSERT 2100 XL is designed to minimize downtime.
Key advantages include:
- Insertion head replacement in approximately 10 minutes
- Product tooling change in approximately 15 minutes
- Easy adaptation to different production batches
- Reduced setup time between projects
These features allow manufacturers to respond quickly to changing production requirements.
Applications
The PININSERT 2100 XL is ideal for manufacturing:
- Power modules
- Automotive electronic assemblies
- Electric motor components
- Industrial control systems
- Battery Management Systems (BMS)
- Renewable energy electronics
- High-current PCB assemblies
- Custom connector applications
