Fully Automated Assembly Line Solution for Single-End NTC Sensor Finishing Line

Project scope

For this November 2022 electronics sensor manufacturing project, we designed an NTC finishing line for single-end components. The process includes wire cutting and boarding, soldering, encapsulation, shell insertion, resistance and hipot testing, and later-stage terminal and plastic-seat assembly. That makes the scope a fully automated assembly line solution application for ntc sensor finishing line.

Flow objective

Rather than stopping at basic resistor joining, the plan extends into the downstream finishing steps needed to move product toward final shipment. That makes it a broader finishing-line design than a simple soldering cell.

Linked finishing operations

The line has to bridge automatic and manual work across several stations: boarding, soldering, encapsulation, shell insertion, board-level resistance and hipot testing, and manual terminal/plastic-seat work. The challenge is not one machine but overall line continuity.

Daily output planning

We sized the design around a 30,000-piece daily target. That requires not only machine selection but also planning for line boards, encapsulation frames, turnover carts, potting fixtures and operator assignments.

Quality verification

The line includes both resistance and high-voltage testing, which raises fixture and test-handling requirements. Later assembly steps such as terminal crimping and plastic-seat insertion also add dimensional and handling risk after the primary sensor body is completed.

Automated front-end

We start with automatic wire cutting and boarding, followed by single-end component feeding, shaping and soldering. The later slides quantify the number of line boards required to support the targeted daily throughput and the board recirculation cycle.

Encapsulation and fixture sizing

The plan specifies one encapsulation machine for the targeted daily output, plus turnover carts and encapsulation frames sized around the stated production volume. It also sizes potting fixtures for the downstream shell-insertion and dispensing process.

Testing and downstream assembly

The testing section uses automatic resistance and hipot verification on fixture-loaded boards. After testing, the design continues into manual sleeve cutting, terminal insertion and plastic-seat assembly so the finishing line covers the later mechanical steps as well.

Key technical parameters

Area	Configuration	Planning value
Daily line target	Full finishing flow	30,000 pcs/day
Line boards	Board return cycle from first process to board removal	5,000 boards
Boarding machine	One cutting and boarding machine	3,000 pcs/hour
Single-end welding	One single-end welding machine	3,000 pcs/hour
Encapsulation	One encapsulation machine	6,000 to 7,000 pcs/hour
Shell potting	One potting machine with 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
Terminal and plastic-seat operation	Semi-automatic terminal/plastic-seat equipment	1,200 to 1,500 pcs/hour per unit

Cost and labor model

The configuration includes 120 encapsulation frames, ten turnover carts, 150 potting fixtures, line boards, one resistance/hipot tester and a glue-preparation section. The original planning model estimates about CNY 262,700 in tooling, CNY 2.516 million in equipment and CNY 2.7787 million total investment. It keeps about 6.2 operators on line while reducing about 22 manual positions, with an estimated payback period of around 16 months at the stated labor-cost assumptions.

Proposed operating result

The resulting concept is a human-machine finishing line designed to carry product from boarded wire through tested and mechanically finished NTC assemblies. It is built around quantified fixture, board and operator planning instead of treating each station in isolation.

Planning depth

Our work goes beyond machine photos and includes daily-output calculations, tooling counts, operator allocation and payback modeling. That gives the customer a line-level deployment plan rather than only a loose equipment recommendation.