Fully Automated Assembly Line for 58-Ohm NTC Sensor Finishing Line

Project scope

The electronics sensor project from September 4, 2023 lays out an NTC finishing line built around 58-ohm resistor joining, board encapsulation, shell insertion, dispensing and automated resistance-plus-hipot testing. That makes the scope a fully automated assembly line application for ntc sensor finishing line.

Planning objective

Our work does not stop at a process sketch. We quantify fixture counts, equipment counts, labor allocation and expected payback so the customer can evaluate both the production process and the investment logic.

Multiple linked stages

The line has to coordinate cutting and boarding, resistor shaping and soldering, encapsulation, shell insertion, manual sleeve work and auto testing. That creates a typical finishing-line problem: several medium-speed stages that need consistent handoff and fixture return.

Fixture and operator balancing

We sized not only machines but also supporting assets such as turnover carts, encapsulation frames and potting fixtures. That sizing translates into planned on-line labor and projected labor savings for a customer comparing automation against a manual baseline.

Testing requirements

The test stage combines resistance and high-voltage verification, so it needs dedicated fixtures and stable loading logic rather than simple bench testing.

Line configuration

We begin with automatic boarding and 58-ohm resistor soldering, then move into encapsulation and shell-insertion stages. The middle process is supported by five turnover carts and sixty encapsulation frames, plus 150 potting fixtures for the later process.

Testing section

The testing segment is planned around one automatic resistance and hipot test machine. The project presents this as a core quality gate for the finishing line rather than a separate optional station.

Investment model

We specify an estimated tooling investment of about CNY 151,300 and equipment investment of about CNY 1.73 million, for an overall line investment of about CNY 1.8813 million. We also estimate that the automated line reduces on-line labor by 13 people and reaches payback in roughly 14 months.

Configuration and ROI table

Area	Configuration	Planning value
Boarding	One four-wire boarding machine	2,000 pcs/hour
Resistor welding	One dual-station 58-ohm resistor welding machine	1,800 to 2,000 pcs/hour
Turnover	Encapsulation frames and carts	60 frames, five turnover carts
Encapsulation	One encapsulation machine	6,000 to 7,000 pcs/hour
Shell potting	One potting machine plus 150 potting fixtures	4,000 to 5,000 pcs/hour
Resistance and hipot test	One automatic tester plus 40 turnover test fixtures	3,000 to 4,000 pcs/hour
Planned staffing	Online operators after automation	Six people
Labor reduction	Compared with pure manual production	13 people
Payback model	Based on the stated monthly labor saving	About 14 months

Proposed operating result

The finishing-line plan packages the NTC finishing route into one investment case covering process flow, support fixtures, testing and staffing. It gives the customer a clearer basis for deciding whether to move from manual work toward a more automated finishing line.

Business value

Because the design includes equipment counts, labor reduction and a payback estimate, it is positioned as an implementation-ready business case rather than only a technical concept.