Automated Production Line for NTC Production Line with Process Fixtures

Project scope

For this February 2025 electronics sensor manufacturing project, we designed an NTC production line for 58-ohm resistor-based sensor assemblies. The target flow combines automatic wire cutting and boarding, resistor forming and soldering, board encapsulation, shell insertion, dispensing and final performance testing. That makes the scope an automated Production line application for ntc sensor production line.

Production objective

We designed the line as a linked process rather than isolated machines. We connected front-end boarding, soldering, encapsulation and later-stage testing so that the customer can standardize the full production route and fixture turnover.

Multi-stage process coordination

The plan has to connect several different process types: wire preparation, resistor feed and shaping, soldering, board-level encapsulation, shell insertion, dispensing, baking and final testing. That creates both material-flow complexity and fixture-management pressure.

Capacity and fixture turnover

We targeted daily output in the 20,000-piece range. It therefore has to account for production boards, encapsulation frames, turnover carts and potting fixtures so that the back-end curing and testing steps do not slow down the front-end automation.

Testing consistency

The testing stage is not limited to a simple room-temperature check. The project includes high-voltage insulation testing plus resistance testing in controlled 25 C and 85 C water-bath conditions, with data capture and NG sorting.

Front-end automation

We specify that the wire cutting and boarding section is configured with eight wire-feeding shafts and can run around 1,800 to 2,000 pieces per hour, depending on wire length. It is paired with a dual-station soldering setup for the resistor-to-wire joining step.

Encapsulation and turnover planning

For board encapsulation, we specified one automatic encapsulation machine with hourly capacity around 10,000 to 14,000 pieces. We also quantified the downstream turnover plan with ten turnover carts and 120 encapsulation frames for a 20,000-piece daily target.

Shell insertion and testing

The shell-insertion and dispensing section uses two vibratory bowls and four dispensing heads, with stated capacity around 4,000 to 5,000 pieces per hour. The testing section combines resistance and high-voltage verification, database-backed data capture and automatic NG separation. We also account for customer-reference equipment and fixtures for this stage.

Key technical parameters

Area	Configuration	Planning value
Wire cutting and boarding	Eight wire-feeding shafts, five reels loaded at the same time	1,800 to 2,000 pcs/hour, depending on wire length
Wire-length range	Automatic cutting, stripping, fluxing, tinning and board loading	50 to 1,500 mm
Resistor joining	Dual-station resistor forming, lead cutting and welding	1,600 to 2,000 pcs/hour
Daily front-end target	One boarding machine plus one welding machine	16,000 to 20,000 pcs in a 10-hour shift
Encapsulation	One automatic encapsulation machine	10,000 to 14,000 pcs/hour
Shell insertion and dispensing	Two bowl feeders and four dispensing heads	4,000 to 5,000 pcs/hour
Performance test	Hipot plus 25 C and 85 C resistance testing	2,000 to 4,000 wires/hour

Fixture and turnover sizing

For a 20,000-piece daily target, we sized the line around 2,000 line boards: 1,000 boards for the active daily requirement and another 1,000 boards to cover downstream return-cycle time. The encapsulation loop uses 120 encapsulation frames and ten turnover carts, with each frame carrying 15 fixtures and 20 parts per fixture. Shell insertion uses about 150 potting fixtures, with each fixture set carrying 300 parts.

Proposed operating result

The resulting line concept gives the customer a connected process from boarding and soldering through encapsulation, shell insertion and final test. The design is configured around a 20,000-piece daily output level with dedicated fixture and turnover planning rather than ad hoc manual transfers.

Labor and equipment impact

We estimate that the line can reduce manual work across multiple stations: about five operators in the boarding and resistor-welding section, three in encapsulation, five in shell insertion and dispensing, and one in the performance-test stage. The testing cell also improves quality control by saving test records, marking OK/NG results and supporting fixture-based handling instead of isolated bench checks.