Project Objectives
The client required an electronics assembly automation solution for smoke alarm production, with a focus on automating the lamp holder assembly process.
The product integrates multiple precision electronic components, including sensors, LED modules, emitter and receiver tubes. In the existing production process, component forming, soldering, and assembly were mainly handled manually, resulting in inconsistent quality and limited production efficiency.
To improve manufacturing stability and meet growing demand, the client aimed to implement a fully automated workflow covering:
Component forming for sensors, LED, emitter and receiver tubes
Precision soldering of electronic components
Lamp holder and housing screw fastening
AOI inspection for assembly quality control
Final encapsulation and sealing
Laser marking for product traceability
By introducing a standardized electronics assembly automation process, the solution helps ensure consistent product performance, reduce reliance on manual labor, and support scalable production.
Our Solution
Process Flow
The line adopts a modular layout with sequential stations for PCB processing, assembly, soldering, inspection, and final assembly. Automated transfer systems and robotic handling help ensure smooth material flow, stable operation, and full product traceability.
Key Equipment Solutions
The line is equipped with a range of automated systems, including PCB feeding units, precision soldering machines, component forming equipment, and multiple housing feeding systems.
Vision inspection systems and sensors are integrated for in line quality control, while industrial robots handle key assembly and transfer processes. Barcode tracking devices are applied throughout the line to support full traceability.
| No. | Equipment Name | Quantity |
|---|---|---|
| 1 | Varistor Feeding and Lead Forming Machine | 1 Set |
| 2 | Automatic PCB Feeding Machine | 1 Set |
| 3 | Cartesian Soldering Machine | 3 Sets |
| 4 | Upper Housing Automatic Feeding Machine | 1 Set |
| 5 | Lower Housing Automatic Feeding Machine | 1 Set |
| 6 | Base Cover Automatic Feeding Machine | 1 Set |
| 7 | Labyrinth Automatic Feeding Machine | 1 Set |
| 8 | Lead Cutting and Forming Machine | 3 Sets |
| 9 | Barcode Scanner | 36 Sets |
| 10 | Contact Displacement Sensor | 10 Sets |
| 11 | CCD Vision System | 8 Sets |
| 12 | Industrial Robot | 16 Sets |
Specifications
| Specification | Details |
|---|---|
| Equipment Size | 16000 × 2600 × 1800 mm (L × W × H), subject to final design. |
| Incoming Product | Injection molded parts |
| Working Efficiency | 600 to 700 PCS/H |
| Drive Method | Servo motors, screw rods, and robotic handling |
| Positioning Accuracy | ±0.02 mm |
| Motion Guide | Imported silver rail guides and screw rods |
| Control System | PLC and touchscreen control system |
| Programming Method | PLC |
| Power Supply | 380VAC, 50HZ |
| Air Pressure | 0.5 MPa |
| Machine Weight | To be confirmed |
| Communication Port | USB and Ethernet |
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