Automated Assembly Line Solution for 58-Ohm Resistor NTC Production Line

Project scope

We developed an electronics sensor production-line and investment package for 58-ohm resistor-based NTC products. It covers boarding, soldering, encapsulation, shell insertion, cleaning, glue preparation and performance testing. That makes the scope an automated assembly line solution application for ntc sensor production line.

Production objective

We designed the line to replace a more fragmented manual flow with a structured production route that still allows some manual intervention in the later stages. We sized several stations around a daily output target of about 20,000 pieces.

More than a basic joining line

This design includes several support processes that many simpler NTC plans leave out: ultrasonic cleaning, rolling glue, automatic glue mixing and vacuum glue mixing. Those extra process blocks increase coordination complexity but are important for stable encapsulation quality.

Capacity and manual handoff

The process still contains manual steps such as board insertion, supplemental glue and some testing actions. The challenge is therefore to automate the high-repeat sections without pretending the whole route is fully unmanned.

Investment scrutiny

Because this file includes quotation content, the design also has to justify capital spending. The later slides explicitly discuss equipment cost, labor saving and payback.

Front-end line sizing

The boarding section is rated around 2,000 to 2,200 pieces per hour depending on wire length, while we paired it with a dual-station soldering process for resistor joining.

Cleaning and glue management

The cleaning section uses an ultrasonic cleaning line rated at 24 frames per hour with two cleaning passes and one drying pass. Downstream, we added a rolling-glue machine, an automatic glue-mixing machine with ratio control and weight monitoring, and a vacuum glue mixer.

Shell insertion and testing

The shell-insertion and dispensing station is rated around 4,000 to 5,000 pieces per hour. The later testing section supports room-state or constant-temperature resistance testing plus data collection, so the line can capture process results rather than only sort OK and NG manually.

Key technical parameters

Area	Configuration	Planning value
Daily line target	58-ohm resistor NTC route	About 20,000 pcs/day
Boarding	One boarding machine	2,000 to 2,200 pcs/hour
Resistor welding	One dual-station welding machine	1,600 to 2,000 pcs/hour
Ultrasonic cleaning	Two cleaning passes and one drying pass	24 frames/hour, up to about 70,000 pcs/day if run full day
Encapsulation	One automatic encapsulation machine	10,000 to 14,000 pcs/hour
Turnover	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
Test-data collection	Computer test system plus collectors	Resistance data capture and database storage

Investment package

The equipment package includes a boarding machine, welding machine, encapsulation machine, shell-insertion dispensing machine, computer test system, data collectors, automatic rolling, automatic glue mixing, vacuum mixing and ultrasonic cleaning. The original cost model estimates CNY 159,100 in fixtures and about CNY 1.3661 million in equipment, with a total package around CNY 1.5207 million. Compared with manual operation, the model estimates a 17-person labor reduction, about CNY 136,000 in monthly labor saving and an equipment payback period of roughly ten months.

Proposed operating result

The system gives the customer a fuller NTC production route that covers not only joining and encapsulation, but also cleaning, glue preparation and traceable testing. It is therefore positioned as a more complete process package than the base finishing-line projects.

Cost and payback

The investment planning includes an equipment investment estimate of about CNY 1.3661 million and an expected payback period of about ten months. That makes this project one of the clearest business cases in the batch.