Electromechanical methods of assembling PCBs refer to the combined efforts of using electronic and mechanical processes for the circuit boards’ operations. This article highlights the basics of electromechanical assembly, the different variants you can choose from and some of the benefits.
What is Electromechanical Parts Assembly?
It refers to the process of using mechanical and electronic components, as well as subassemblies to manufacture an electronic device. The need for this process is buoyed by the need to make electronic devices fully electronic.
At the core of electromechanical assembly process is the creation of a definitive unit and the creation of a seamless integration of the product’s mechanical and electronic aspects.
Here are some quick facts about the electromechanical assembly manufacturing process:
- It allows for the creation of a fully-functional system – one that connects the electronic components to the mechanical elements.
- The assembly process also leads to the creation of a system that utilizes electronic current for performing mechanical operations.
Electromechanical Components List
The list of components used for the electromechanical assembly often alternate between the mechanical and electronic elements. However, it is also possible to use other components, such as subassemblies.
Mechanical Components
The following are some of the mechanical elements used in electromechanical assembly:
- Casings
- Motors and;
- Gears
Electronic Components
The following is a list of some of the electronic components used for electromechanical assembly:
- Sensors
- Printed Circuit Boards (PCBs)
The list of electromechanical components also includes the following:
- Programmable Logic Controllers (PLCs)
- DIN Rails
- Power switches
- Power supplies
- Cable and wire assemblies
- Enclosures
- Electric motors and;
- Varieties of circuitries.
Categories of Components Used in Electromechanical Assemblies
You may have thought that the assembly process uses just the combined components from both electronics and mechanics. However, there are three (3) broad categories of these parts, as discussed below:
Mechanical Components
The function of these parts is to account for the visible (physical) attributes of the electronic device. Parts like fasteners, motors, enclosures and gears are used for this purpose.
Electronic Parts
These components are used to build the electrical functionality of the electronic devices. The likes of capacitors, Integrated Circuits (ICs), Printed Circuit Boards (PCBs) and resistors are used here.
Electromechanical Parts
These are the combined components functioning both as electronics and mechanics. Connectors, switches, and solenoids are examples of the parts that have properties of both mechanical and electrical devices.
Types of Electromechanical Assembly Services
The complexity of the device and the targeted applications are some important considerations for the electromechanical assembly types.
These are some of the common ways to assemble electronic devices:
1. Cable and Harness Assemblies
This process refers to the use of wires or cables meant for transmitting electrical signals within the device.
Some of the cable and harness parts are:
- Ties: these are used to affix the wire harness to the device.
- Wires and Cables: these are designed to convey the signals and electrical current within the device.
- Insulators: these components protect the electronic devices’ components from touching the environment and from touching each other.
- Fuses: these are in place to regulate electrical current, and in extension, reduces the risks of power-induced damages to the device.
- Connectors: these are used to connect the wires and cables in the electronic device.
- Relays: the function of the relays is to turn on and off the power in the high-amperage circuits.
2. Mounting Rails
Also called the DIN Rails, these are used to mount several other components within the electromechanical assembly.
3. Motor Assemblies
These are the types of electromechanical assembly used for ensuring movement within the electronic device.
4. Switch and Sensor Assemblies
Also called the control panels, they help in bolstering the interactions and controls of the electronic device.
They are broadly categorized into:
Sensor Assemblies
These refer to the parts used for converting light, sound, motion and heat into the corresponding electrical signals.
Examples of the components used for the sensor assemblies are:
- Connection Heads: these parts enable the sensor wires’ connection to the transmitter.
- Sensing Elements: these components are used for detecting proximity and the physical properties, such as radiation and temperature.
- Transmitters: these are used to transfer the data (pieces of information) obtained about the targeted property.
- Housings: these are used to protect the sensor-related components.
Switch Assemblies
These components are primarily used for connecting or disconnecting the power supply to the electrical components.
Examples of the switch assembly components are:
- The Switching Mechanism: this is a pushbutton used for controlling the electronic device’s operations.
- Contacts: these parts allow for the flow of electric current to the device’s switch.
- Wiring Harness: the harness provides the pathway for the entry and exit of electric current from the switch. It is also used for holding the electric switch in position.
5. Power Supply Assemblies
These are the components used for the conversion and distribution of electrical current within the electronic device. These parts include:
- Regulators: these are used for reducing the filter’s ripple voltages.
- Transformers: these components are used for modifying the voltage coming into the system.
- Filters: are used for smoothing out the waves in the Direct Current (DC) output. This happens after the rectification process.
- Rectifiers: used to convert the incoming voltage from Alternating Current (AC) to Direct Current (DC).
6. Box Builds and Integrations
This infers to the process of building full systems of electromechanical assembly called box builds. We can also handle the integrations for you, such as integrating a circuit board into full harnesses, enclosures and a front panel assembly equipped with switches and connectors.
7. Panel Assemblies
This type of electromechanical contract manufacturing requires the integration of the components into panels. The aim of the integration is to streamline the process of distributing power into the connected circuits.
The panel assembly process includes wiring the panel, positioning the components in the back panel and drilling the holes for mounting the hardware.
8. Transformer Assemblies
The process of transformer assemblies involves aiding the transfer of electrical current between multiple circuits.
The process includes the insulation of materials, lamination of the core, making primary and secondary windings.
The Benefits of Electromechanical Assemblies
Despite the complexities, using the electromechanical process of assembling electronic devices comes with some perks, such as:
Device Modernization
Electromechanical assemblies support the reevaluation and upgrade of the existing electronic devices.
Specialized Services
You can get specialized electromechanical assembly services from the Contract Manufacturer (CM). With the longstanding years of experience and the use of specialized equipment, the electromechanical assembly technician has the know-how to optimize the complexity of the electronic devices.
Prototyping
The support for prototyping and testing allows for the early-stage validation of the electromechanical assembly products.
Affordable Electronic Product Manufacturing
You also get to save up on extra costs when using the electromechanical assembly. Thanks to the box build and integration process, you can reduce the overall production costs.
The electromechanical contract manufacturing company will be handling most aspects of the product, such as:
- Component sourcing
- Handling the facility, labor and equipment costs.
- The manufacturer’s access to a set of established supply chain networks also helps you to save costs on logistics.
How to Choose Electromechanical Contract Manufacturing Companies
Want to work with a Contract Manufacturer (CM) for your electronic device production? Here are some of the tips on choosing the best company:
Quality Assurance
The products or electrical devices should meet the minimum quality standards. Therefore, the company should have the relevant facilities and certifications to offer electromechanical assembly services.
Check the Technical Capabilities
This refers to the Contract Manufacturer (CM)’s ability to handle your electronic device project, as per your requirements.
The manufacturer needs the know-how and pieces of equipment to make this work.
Volume of Orders
Does the electromechanical assembly CM have what it takes to produce the volumes (numbers) of electronic devices you want?
First, find out if the company supports micro electromechanical assembly, which means that it allows for the production of a few products.
The manufacturer should also be able to handle large-volume orders.
Track Record
This refers to the Contract Manufacturer (CM)’s many years of experience. It also refers to the different projects it has been able to process, thanks to the extensive years of experience.
The reason for this consideration is that an experienced CM is the one that can easily detect and fix issues, as well as produce your devices, as per the requirements.
Box Build Electromechanical Assemblies
Does the company offer box build solutions? If it does, it makes sense, as it saves you time and money. The specifications of the box build solutions include sourcing the components and managing the entire electromechanical assembly in-house.
How to Get Started with Electromechanical Assembly
Haven satisfied yourself that using electromechanical assembly can improve your electronic projects, start by contacting a professional manufacturer. We will help you make custom-built solutions that match your projects’ preferences, serve the needs of the target market and save you costs.
You can be sure of getting your electronic devices’ electromechanical assembly solutions handled in-house by our experienced engineers and all these will be completed in the shortest lead time possible.
