Project Objectives
As demand for NTC sensors continued to grow, the manufacturer needed a more efficient Sensor Assembly Line to handle a long and detail sensitive production process. The product required multiple steps, including wire cutting, tinning, component forming, welding, soldering, inspection, cleaning, epoxy coating, dispensing, curing, and final electrical testing. Manual production made it harder to maintain stable throughput, consistent quality. Based on the required process flow and production target of up to 20,000 pieces per day, the project called for a custom assembly solution that could streamline production, improve process control, and support more reliable high volume manufacturing.
Our Solution
Assembly and Test Process
We developed a custom Sensor Assembly Line to turn a labor intensive production flow into a more streamlined and controllable manufacturing system. the solution combined key assembly, inspection, encapsulation, and testing stages into one coordinated workflow, improve process consistency, and support more stable daily production.
To match the product requirements, the line was designed to support dual 24 and 26 AWG wires, maintain tight dimensional control, and meet overall quality targets during continuous production. We also adopted a practical human machine collaboration approach by automating the most repetitive and precision sensitive steps while keeping selected operator assisted stations where flexibility, adjustment, and process stability were still important. This made the line more suitable for real production conditions while supporting a daily capacity of about 18,000 to 20,000 PCS/day
Equipment Solution
Assembly
This assembly equipment performs sensor forming, lead trimming, and welding in one streamlined process. It is designed for both 24 and 26 AWG wires and can produce about 1,800 to 2,000 PCS/H.
AOI
The CCD inspection equipment automatically checks semi finished sensor assemblies for cold solder joints, weld offset, and other visible welding defects after soldering. It records inspection data in real time and filters out defective products before the next process, helping improve product consistency and overall quality control. The system can handle about 1,800 to 2,000 PCS/H.
Encapsulation
This encapsulation equipment performs automatic adhesive coating and potting. It helps create a more stable sealing process for NTC sensor assemblies, with a capacity of about 6,000 to 7,000 PCS/H for adhesive coating and 4,000 to 5,000 PCS/H for potting.
Testing
The testing equipment is used to perform resistance testing at 25°C and 85°C and automatic hipot insulation testing, while recording test data for traceability and quality control. The system delivers a testing capacity of about 3,000 to 4,000 PCS/H.
Interested in our solutions?
- Contact our experts to learn more about Robotlyne’s assembly solutions.
- See if your project is feasible fast. Get a clear scope, timeline, and Free ROI Analysis.
