Mechanical and electrical assembly services are highly complex tasks that cannot be fully completed without an experienced team. At Haibo, we can leverage our over 16 years of experience and strong supply chain to meet all your mechanical and electrical assembly needs. The following is the normal process of mechanical and electrical contract manufacturing:

PCB manufacturing, PCB component sourcing, and PCB assembly. Ensure that electronic components are functioning properly.

●If all other mechanical or electronic components are not manufactured internally, procurement is required, such as metal/plastic boxes, DIN rails, frames, power supplies, input/output devices, etc.

●According to customer requirements, all cables/wires are correctly fixed on DIN rails.

●Connect all electronic components and program firmware and software.

●Perform functional testing on fully assembled systems.

●Aging testing, reliability testing, and environmental testing.

●Labels and packaging.

As mentioned above, electromechanical assembly requires many elements, such as PCBs, cables, rails, housings, power supplies, pneumatic devices, input and output equipment, displays, actuators, gears, sensors, etc. Here, we will discuss the key elements required for electromechanical assembly workers to complete the electromechanical assembly process.

Cables and wires are used to physically and electrically connect components and equipment to transmit energy and signals, and are widely used in the aerospace, automotive, and military fields. Computers are also used to generate cable component paths to improve design efficiency. Cable components play an important role in electromechanical assembly. When designing the path, the engineering factors and material characteristics of the cable should be considered. Cable components can be manually completed by operators or grabbed by robots, depending on the order quantity and the capabilities of the mechanical and electrical assembly workers.

Power supply is a widely used electromechanical product for all consumers. Almost 100% of electricity is generated by motors that can convert a form of energy into electrical energy. The components of the power supply assembly include but are not limited to transformers, rectifiers, and regulators. Power supply is very important in electromechanical components.

An example of electromechanical assembly is switches and sensors, which are widely applicable in any industrial environment. Some examples include linear limit switches, which change the contact state when there is physical contact between an object and the switch, and rotary limit switches, which allow or prevent current when closed or opened. Meanwhile, sensors are used to convert signals such as sound, heat, light, and motion into electrical signals. The sensor component will include a sensing element, a housing, and a transmitter. Any electromechanical assembly worker should ensure that all switches and sensors are correctly placed.

Printed circuit boards are widely used in electronic devices because they serve as platforms for various electronic components that can perform various functions. Electronic components are picked up and placed on the circuit board, and the conductive pads of the components and circuit board are metallurgically connected using solder. There are several types of printed circuit boards, such as flexible or rigid circuit boards, single-layer or multi-layer. Then integrate the PCBA into mechanical components to produce so-called 'boxed' components. Printed circuit board assembly is crucial for electromechanical assembly services, as electronic products cannot function properly without a perfect PCB.

After all the materials required for electromechanical assembly are ready, they need to be assembled in a plastic or metal casing with DIN rails and frames to form a complete electronic device. In most cases, customized casings, DIN rails, and frames are required. In the final assembly stage, electrical and mechanical assemblers place and secure all components (such as PCBs, cables, switches, sensors, power supplies, input and output devices, relays and safety components, and pneumatic devices) in the housing with the support of DIN rails and frames.

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.

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.

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.

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.

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.

We use electromechanical systems in our daily activities. Common examples include laptops and camera hard drives, which typically consist of dual electromechanical systems, drives, and servers. Mechanical and electrical equipment converts electrical energy into mechanical energy. In short, the conversion process allows most systems to perform their intended functions, such as activating the engine's starting system and powering the car's fan.

The following are the main driving factors for the growth and expansion of electromechanical systems:

The rapid development of actuators, integrated circuits (ICs), microprocessors, and power electronics technology.

Industrial and social demands.

Compared with other types of systems, electromechanical systems have economy and superiority.

Economically efficient manufacturing technology

For example, in industrial applications, electromechanical systems are equipped with actuator robots and automation systems, cargo handling technology, and servo motors for controlling valve opening and closing. Mechanical and electrical systems can usually be divided into traditional mechanical and electrical systems and micro scale mechanical and electrical systems. Both systems are based on overall physics and analysis, but differ in cost and manufacturing technology. Mechatronics assembly refers to the final assembly of electronic equipment using mechanical and electrical components.

Now that we have introduced the concept of electromechanical equipment, let's review some of the history of this technology. The 20th century began with the invention of direct current and alternating current by Edison and Tesla, which opened the embryonic stage of the power industry. The power industry also expanded from traditional power generation and consumption to innovation in the fields of sea, air, and ground transportation.

In the mid-1900s, the birth of computers and thyristor rectifiers (devices that convert AC voltage to DC voltage) propelled progress in the field of electricity, including smart grids, electric drives, airplanes, and ships. In the 1940s, 1950s, and 2000s, with the outbreak of World War II, electromechanical systems underwent further development, thanks to the invention of military power equipment. After the war, with the development of computers, the demand for consumer electronic products increased. Nowadays, with the introduction of Micro Electro Mechanical Systems (MEMS), the applications of electromechanical devices are infinite and are developing towards miniaturization. Mechanical and electrical assembly suppliers play an important role in electronic manufacturing.

Mechanical and electrical assembly is a very complex process. In order to avoid problems during and after production, mechanical and electrical assembly personnel should consider key factors during the design phase. Please refer to the following details that mechanical and electrical assembly companies should pay attention to.

The product development roadmap begins with a set of requirements from the customer. The purpose of requirement definition is to develop a project management plan, schedule, and technical review. The design document includes these requirements, work instructions, and product specifications. The product features are also described at this stage. Clear and detailed requirements and specifications will enable us to design and manufacture products accordingly. In fact, the scope of work, technical specifications, and roadmap are still easily modified, especially during product design validation, which requires multiple iterations to meet functional requirements, cost, and quality or reliability standards. Understanding the functions and uses of electromechanical assembly is very important.

Material selection is a crucial step in the design of electromechanical equipment. The selection criteria largely depend on the specific application. Some aspects that need to be noted include corrosion resistance, price, processing performance, and usability. Electromagnetic performance is also important, especially for solenoids and brakes primarily used in automotive applications. The components to be used should also comply with regulatory standards such as RoHS (Restriction of Hazardous Substances)/REACH (Registration, Evaluation, Authorization, and Restriction of Chemicals).

In the process of mechanical and electrical assembly design, the thermal characteristics of each component should also be considered. These characteristics include thermal conductivity, heat capacity, and material density. The thermal behavior and stress effects of materials are simulated using complex techniques such as FEA software (finite element analysis). The difference in thermal expansion of materials may lead to delamination and warping effects, and become the root cause of failures during assembly and application processes.

The optimal design of electromechanical equipment can balance the final performance and cost impact. This can be achieved by adopting best practices and design rules integrated into the DFM process (design for manufacturability). A useful strategy for simplifying design is to divide design requirements into two categories: "if there is, it is better" and "must have", with the former being a secondary consideration and the latter being more important aspects related to product functionality. DFM helps engineers consider the simplicity of manufacturing and assembly while meeting product functional requirements. The design rules set some limitations on size and geometric rules so that parts can be easily manufactured and assembled. In the process of mechanical and electrical assembly design, designers should always understand the manufacturability of each component to avoid delays and troubles in future production.

If pursuing cost-effective FPC manufacturing services, choosing a Chinese manufacturer is the best choice. As a manufacturing powerhouse, China has abundant resources, cheap labor, and a large number of technical personnel. We recommend Haibo, a Chinese FPC assembly service provider with over 10 years of experience, who has performed outstandingly in various aspects

Efficient and reasonable quotation:There is an efficient quotation process to assist you in making decisions, providing reasonable prices and highly competitive quotes in China.
High quality and reliable products:Produce high standard printed circuit boards, manufacture and test according to specifications, international standards, and internal controls, and conduct pre production inspections to ensure robust processes.
Quick and on-time delivery:The assembly equipment is in good condition, with high productivity, minimal downtime, short delivery time, and also provides urgent services.
Timely and effective response:Always respond to customer needs, provide accurate information, answer questions through multiple channels, and offer one-stop services.
Strong technical strength:China's FPC manufacturing technology is leading, and Haibo has a complete SMT solution that covers assembly, inspection, and other capabilities. It also provides prototype production and customization services.