CLIENT & CHALLENGE
Precision Wire Cutting and Soldering Module for NTC Sensors
A leading NTC sensor manufacturer wanted to expand production capacity and reduce operating costs as market competition intensified. Its previous assembly process depended on manual wire soldering, which restricted throughput and created variability in sensor performance. We replaced these manual steps with a high precision automated assembly line designed to improve productivity, increase accuracy, and deliver more consistent solder joint quality.
Our approach
After working closely with the client’s engineering team to map the production process, we developed a highly synchronized two station automated assembly line. The modular system replaced variable manual labor with a continuous, precision controlled workflow that improved material utilization and overall process stability.
The system is divided into two core units: the Upstream Station handles high-speed wire feeding, precision cutting, stripping, and tin dipping in one seamless sequence. The Downstream Station features a dedicated robotic soldering machine that processes tray-loaded wires with micron-level consistency. These stations are perfectly coordinated via an intelligent tray-handoff mechanism to maintain a non-stop production cadence.
Driven by significant labor reallocation and throughput gains, this investment is engineered to achieve a full ROI within 12 months, supported by reduced per-shift headcount and minimized cycle times.
Fully Automated Production
From wire processing to final soldering, the entire sequence operates as a fully unattended, high-speed workflow.
Consistency and Stability
Powered by high-torque servo motors and an intuitive PLC interface, ensuring repeatable accuracy across millions of cycles.
Expansion and Upgrades
Engineered with standardized interfaces to allow for future capacity expansion and seamless hardware adaptations for diverse sensor specifications.
MES and WMS Compatible
Our in-house software suite provides native connectivity for real-time data tracking, predictive maintenance, and total production transparency.
wire feeding
cut to length
Resistor lead forming
tin dipping
tray loading
soldering
The Results
Prior to final delivery, we completed a comprehensive one-month trial production phase. The implemented automated assembly line delivered a significant increase in throughput, reduced manufacturing costs, and achieved a high yield with industry-leading product consistency.
The machine delivers consistently high quality resistor soldering, with neat joints and excellent consistency. It has exceeded our expectations.
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- Automation Specialist
- Hunter
Robotlyne is a leading manufacturer of automated equipment and a developer of proprietary industrial software. We engineer and build high-performance solutions designed to synchronize your entire production ecosystem. With 20+ years of expertise in hardware manufacturing and software development, we deliver data-driven smart factory strategies that drive measurable efficiency and long-term ROI.
