Automated Production System for NTC Production Line with Database-Backed Testing

Project scope

The project from March 30, 2024 describes an NTC production line that combines wire cutting and boarding, soldering, encapsulation, potting, curing, ultrasonic cleaning and resistance-testing operations. That makes the scope an automated Production system application for ntc sensor production line.

Product-flow objective

The plan links front-end joining with later shell insertion and testing instead of leaving those steps as disconnected manual islands. It also includes database-backed test collection in the later performance-test stage.

Hybrid automation flow

The line still contains manual steps such as inserting boards into shells, supplemental glue and manual packaging, while also introducing automated cutting, soldering, cleaning, encapsulation and shell-dispensing equipment. The challenge is to keep those mixed steps synchronized.

Cleaning and cure logistics

Because the design includes ultrasonic cleaning plus baking and cure stages, it must also manage turnover carts, encapsulation frames and process recirculation timing. Otherwise the back-end flow would bottleneck the earlier automation stages.

Testing traceability

The testing segment requires more than a pass/fail check. The workflow collects resistance test data in a database, with OK and NG indication logic built into the test flow.

Front-end line sizing

We sized the cutting and boarding equipment around 1,600 to 2,000 pieces per hour and the dual-station welding section at roughly the same range. For a 20,000-piece daily target, we recommend one boarding machine and one welding machine plus about 2,000 line boards.

Cleaning and encapsulation

The cleaning section uses an ultrasonic cleaning line rated at 24 frames per hour, with two cleaning passes and one drying pass. The encapsulation section uses one automatic encapsulation machine with capacity around 10,000 to 14,000 pieces per hour, plus 120 encapsulation frames and ten turnover carts.

Shell insertion and testing

The shell-insertion and dispensing station uses vibratory-bowl feeding with stated capacity around 4,000 to 5,000 pieces per hour. The performance-testing stage supports resistance testing, PLC-linked judgment and database storage of test results.

Key technical parameters

Area	Configuration	Planning value
Daily line target	Hybrid automated/manual NTC flow	20,000 pcs/day
Boarding and welding	One boarding machine plus one dual-station welding machine	1,600 to 2,000 pcs/hour
Line boards	Active boards plus downstream return-cycle coverage	2,000 boards
Ultrasonic cleaning	Two cleaning passes and one drying pass	24 frames/hour
Encapsulation	One automatic encapsulation machine	10,000 to 14,000 pcs/hour
Turnover loop	Encapsulation frames and carts	120 frames, ten turnover carts
Shell insertion and dispensing	Bowl-fed shell insertion and dispensing	4,000 to 5,000 pcs/hour
Data collection	Manual loading, automatic resistance test, PLC judgment	Database storage with OK/NG indication

Glue and cleaning controls

We added ultrasonic cleaning, automatic rolling, automatic glue mixing and vacuum mixing because encapsulation stability depends on material preparation, not only on the dispensing station. The glue-preparation equipment uses recipe control, weighing feedback and vacuum mixing to reduce bubbles, settlement and process variation before encapsulation.

Proposed operating result

We created a complete NTC production route from boarded wire to tested assemblies, with defined cleaning, encapsulation and shell-insertion stages rather than loose handoffs between isolated stations.

Labor and throughput effect

We estimate labor reduction in multiple segments, including cleaning, encapsulation and shell insertion. The line is designed around a 20,000-piece daily output level while preserving manual intervention where the process still needs it.