Zhongwei Electronics NTC Production Line with Process Fixtures

Project scope

The source proposal dated February 11, 2025 describes an NTC production line for 58-ohm resistor-based sensor assemblies. The target flow combines automatic wire cutting and boarding, resistor forming and soldering, board encapsulation, shell insertion, dispensing and final performance testing.

Production objective

The line is designed as a linked process rather than isolated machines. The proposal explicitly connects front-end boarding, soldering, encapsulation and later-stage testing so that the customer can standardize the full production route and fixture turnover.

Multi-stage process coordination

The plan has to connect several different process types: wire preparation, resistor feed and shaping, soldering, board-level encapsulation, shell insertion, dispensing, baking and final testing. That creates both material-flow complexity and fixture-management pressure.

Capacity and fixture turnover

The proposal targets daily output in the 20,000-piece range. It therefore has to account for production boards, encapsulation frames, turnover carts and potting fixtures so that the back-end curing and testing steps do not slow down the front-end automation.

Testing consistency

The testing stage is not limited to a simple room-temperature check. The source includes high-voltage insulation testing plus resistance testing in controlled 25 C and 85 C water-bath conditions, with data capture and NG sorting.

Front-end automation

The proposal states that the wire cutting and boarding section is configured with eight wire-feeding shafts and can run around 1,800 to 2,000 pieces per hour, depending on wire length. It is paired with a dual-station soldering setup for the resistor-to-wire joining step.

Encapsulation and turnover planning

For board encapsulation, the source calls for one automatic encapsulation machine with hourly capacity around 10,000 to 14,000 pieces. It also quantifies the downstream turnover plan with ten turnover carts and 120 encapsulation frames for a 20,000-piece daily target.

Shell insertion and testing

The shell-insertion and dispensing section uses two vibratory bowls and four dispensing heads, with stated capacity around 4,000 to 5,000 pieces per hour. The testing section combines resistance and high-voltage verification, database-backed data capture and automatic NG separation. The source also names customer-reference equipment and fixtures for this stage.

Proposed operating result

The resulting line concept gives the customer a connected process from boarding and soldering through encapsulation, shell insertion and final test. The proposal is designed around a 20,000-piece daily output level with dedicated fixture and turnover planning rather than ad hoc manual transfers.

Labor and equipment impact

The source states that the line can reduce manual work across encapsulation, shell insertion and testing, and it explicitly estimates a labor saving of nine operators compared with more manual production. It also allows part of the later-stage process to reference or reuse customer equipment where appropriate.