Mechanical and electrical assembly, from design to assembly
For electromechanical assembly workers, manufacturing a fully functional electronic device is a very complex task, from concept to design, to component procurement, to PCB and electronic assembly, and finally to testing and inspection. Mechanical and electrical assembly companies require advanced equipment and experienced teams to complete this task.
1. Design process
The design phase of electromechanical products is constrained by existing standards, which specify certain standards regarding tolerances and design rules. The best design is one that meets the functional requirements of the product while balancing cost and quality. Software and computer programs can be used to simulate 3D design (including geometric shapes and tolerances) and display them in a statistical and graphical manner. Design and assembly instructions can be compiled in CAD systems to achieve automatic configuration of robot units such as grippers.
2. Parts procurement
All parts required for electromechanical products are usually purchased by electromechanical assemblers. Please note that each material has a specific delivery time, which will affect the completion of the product. Each part and component should be visually inspected according to size requirements. This quality inspection will help detect potential issues that may affect the subsequent assembly process as early as possible. As emphasized in the previous section, the selection of materials is crucial as it affects the procurement process. The preferred parts are those that can be purchased from multiple suppliers and distributors.
3. Assembly of electrical and mechanical components
Then, the electromechanical products are assembled by electromechanical assemblers who integrate electrical components and mechanical parts together. Electrical components can be manufactured through printed circuit board assembly, which typically involves surface mount technology (SMT). In SMT, electrical components are mounted on printed circuit boards through soldering and reflow processes. The assembled printed circuit board will undergo a separate testing process before being integrated into the final electromechanical product. This is to ensure that only qualified components can proceed to the next step.
Mechanical and electrical assembly is an important step that can be completed automatically or manually. Due to the difficulty in achieving automation in the production of electromechanical products, as there are various component types in the system, most automation is usually applied to the production of large quantities, low mix/variety types. In automation, every action of industrial robots must be programmed and attention must be paid to direction and tolerance.
Manual assembly is also suitable for small batch, high mix electromechanical assembly projects. It has some advantages, especially suitable for fast conversion, especially in situations where the product lifecycle is short. The assembly of electromechanical components can include the welding and installation of electrical components, as well as the tightening, insertion, and fastening of mechanical components.
4. Inspection and testing
Quality inspection is very important in mechanical and electrical assembly. Mechanical and electrical products can be tested through hands-free and manual methods. Use image-based measurement systems and visual algorithms for hands-free and automatic detection. Compare the inspection of each component with the reference image and values. When the measured or inspected values exceed the limit, the component will be rejected. The automatic detection system consists of a camera, measurement software, computer monitor, and light source. This automatic detection is very efficient and can fully meet quality standards. The inspection and testing methods can be designed by mechanical and electrical assemblers or brand owners.
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