Automated Soldering Equipment for Wire-Core Square Pressing and Resistor Welding Cell

Project scope

We designed a compact electronics sensor wire-board processing cell for small-head and 58-ohm resistor welding work. The equipment combines wire-core square pressing, resistor co-welding and secondary flat welding in one process route. That makes the scope an Automated Soldering Equipment application for wire-core square pressing and resistor welding.

The equipment overview defines compatibility with incoming parts 13 to 14 mm long, with a maximum head size of 3 mm. It also defines 24# and 26# wire compatibility, including paired wire and separated wire, with wire lengths from 120 to 1,500 mm and exposed wire length from 15 to 30 mm.

Manual board loading with controlled forming

The process had to keep manual loading and unloading of the wire board while still controlling the forming and welding sequence inside the machine. That means the board transfer, pressing location, welding location and finished-board removal all need predictable positioning.

Dimensional and welding requirements

The finished component target includes a formed head dimension of 9 to 13 mm. After welding, the component head extends 25 to 40 mm from the half side of the wire board. These dimensions create a tight relationship between board locating, press-head alignment and downstream welding access.

Process sequence

We structured the flow around six steps:

1. Transfer the wire board to the square-pressing station.
2. Press the wire core.
3. Transfer the wire board to the welding position.
4. Co-weld the wire core and resistor.
5. Complete secondary flat welding.
6. Unload the finished board.

Machine layout

The machine envelope is 1,400 x 800 x 1,900 mm. The layout is organized around a wire-board transfer and welding group, a board handling group, two square-pressing groups and the main frame group.

Module	Confirmed role
Wire-board handling station	Moves and grips the wire board
Transfer and welding station	Positions the board for welding through a powered guide rail and locating fixture
Square-pressing station	Uses upper and lower welding-head assemblies for wire-core pressing
Integrated line layout	Combines wire cutting and board loading, three-station welding and secondary square-press welding

Proposed operating result

The cell turns a manual board-handling process into a controlled pressing and welding route while keeping the operator-facing loading and unloading method simple. The listed configuration uses single-channel welding and a real-time efficiency target of 1,800 to 2,000.

The resulting system is intended for repeatable wire-core forming before resistor welding, with defined board transfer, locating, pressing and secondary flat-welding steps inside a compact machine footprint.