Project Objectives
The goal of this project was to build an automated assembly and test system for refrigerator NTC sensors that could connect wire processing with sensor assembly in one continuous production line. The system was designed to automate wire cutting and tray loading, welding, glue coating, potting, baking, cleaning, and resistance testing, reducing manual handling between processes while improving consistency, throughput, and product quality.
Our Solution
Assembly and Test Process
We redesigned the assembly and testing process for refrigerator NTC sensors by integrating wire preparation, soldering, adhesive coating, potting, curing, cleaning, testing, inspection, and final packaging into a continuous production workflow.
Equipment Solution
Wire Cutting and Soldering Machine
Integrated workflow: Handles automatic wire feeding, cutting, stripping, tinning, tray loading, adhesive dispensing, and soldering.
High output, low labor: Produces 16,000 to 20,000 pcs/day.
Ultrasonic Cleaning Machine
High cleaning efficiency: Processes 24 trays per hour, with a cleaning cycle of 120 seconds per tray.
Integrated cleaning workflow: Supports inline operation with two cleaning cycles and one drying cycle, with the cleaning tank lowering automatically during the process.
Vacuum Mixing Machine
Improved adhesive consistency: Prevents epoxy adhesive from crystallizing and settling through continuous rolling.
Simple operation: Supports manual loading and unloading with reversible drum rolling.
Automatic Adhesive Coating Machine
High production efficiency: Produces 10,000 to 14,000 pieces per hour.
Stable daily output: Can produce up to 270,000 pieces within a 4 hour operation.
Automatic Housing Insertion and Dispensing Machine
Dual station feeding: Uses two vibrating bowls with four feeding lanes to insert four housings at a time with four dispensing heads.
High output: Produces 4,000 to 5,000 pcs/hou
Resistance Testing System and Data Acquisition Unit
Flexible testing conditions: Performs resistance testing in both dry state and constant temperature water bath conditions.
Data capture and storage: Collects test data and stores it in the database for traceability and analysis.
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