Electromechanical assemblies combine complex circuitry and intricate mechanical components into a cohesive system with advanced functionality. This type of assembly is essential for many high-tech systems to function, including military equipment, satellite communication, medical devices, and more. At Captor Corporation, we support the needs of these and other demanding industries with a selection of reliable electromechanical assemblies.
Understanding Electro-Mechanical Assemblies
An electromechanical assembly is a combination of electrical and mechanical components that are integrated to perform a wide range of functions, such as controlling or generating power. The term encompasses a wide range of wire and cable components that range from subassemblies to box builds. In every application, however, electrical and mechanical components and subassemblies work together to perform a specific function.
Electromechanical assemblies are complex, involving many intricate parts, and their design varies greatly depending on the application. Assembly specialists must follow highly detailed design plans to ensure all mechanical elements and electric circuitry are integrated correctly. Many fabrication techniques are used to complete the assembly, including punching or sawing holes, surface mounting techniques, soldering, and other precision processes.
There are several common assembly types, such as switch and sensor assemblies, panel assemblies, and DIN rail assemblies. The best type in a given application depends on the operation the assembly must perform, where the assembly will be mounted, the type of components involved, and other factors. While each of these assembly types varies in design, they all contain several of the same components, such as wiring, switches, connectors, and terminals.
Switch and Sensor Assemblies
Switches and sensors are two vital elements of any electronic system. Switch assemblies connect or disconnect electrical components to a power supply, while sensor assemblies convert stimuli like sound or motion into electrical signals. Switch assemblies consist of contacts that control the electrical current, a wiring harness, and a switching mechanism. Sensor assemblies typically include sensing elements, protective housings, transmitters, and connection heads.
In certain applications, an electromechanical assembly is integrated into a panel. In this setup, it’s easy to control the distribution of power into the connected circuits. Creating a panel assembly involves steps such as:
- Arranging each component into its correct location along the back of a panel
- Creating holes for each component
- Drilling smaller holes for mounting the involved hardware
- Wiring the panel
DIN Rail Assemblies
Also referred to as mounting rails, DIN rail assemblies simplify the mounting process and ensure that fragile components have adequate space and stability to prevent damage. These assemblies must be configured according to the components and subassemblies involved in each application.
Power Supply Assemblies
This type of assembly converts an electric current to the correct format, frequency, and voltage required to power at least one electric load. A power supply assembly can be incorporated into an appliance or function as a standalone device. The components that make up this type of assembly include:
- Housing to protect any involved components
- A transformer to modify the incoming voltage
- A rectifier to convert the power from AC to DC
- A filter that smoothes DC output waves after they have been rectified
- A regulator that reduces ripple voltages that remain after the filtration
Transformers transfer electrical energy between two or more electrical circuits. They increase or decrease the voltage level according to each application’s requirements. Transformer assemblies generally include the following components:
- A laminated core
- Primary and secondary windings
- Insulation materials
- Other application-specific accessories and tanks, such as cooling tubes, an oil conservator, or a breather
Cable and Harness Assemblies
This type of assembly involves multiple cables or wires that transmit electrical signals or power. While each configuration is application-specific, they are made using many of the same components, such as:
- Cables and wires to transmit power
- Connectors to join the cables and wires to each other and other electronic devices
- Fuses that prevent power surge damage
- Relays that turn the power off and on in high-amperage circuits
- Insulators to protect any involved components from touching each other as well as the environment
- Ties that fix the wire harness to the system or device
Industries Using Electromechanical Assemblies
Many diverse industries rely on electromechanical assemblies to power electronic systems and devices. Some of the most common end-use applications involve power distribution networks, control systems, computer displays, and more. At Captor Corporation, we create custom assembly solutions for the world’s most demanding industries, including aerospace, defense, medical, automotive, and industrial machinery.
The aerospace industry requires compact, reliable, high-precision electromechanical assemblies to accommodate their aircraft systems. The layouts of these assemblies must be custom-developed to the needs of each aircraft. Some common types used in aerospace applications include junction boxes, switch panels, power boxes, cockpit panels, and high-power connectors.
In the automotive industry, carefully designed electromechanical assemblies must deliver a long, reliable operating life while meeting the requirements of various automotive systems. Durability is key for these assemblies. Some of the most common assemblies include speed and temperature sensors, relays, and switching mechanisms.
Within the medical industry, electromechanical assemblies support sustainable energy usage, increase motion control precision, and create powerful yet compact tools. Some common applications include drug delivery systems, cardiac defibrillators, IV pumps, MRI machines, and internet-connected medication monitoring systems.
Military and defense assemblies must be precise, compact, and durable enough to withstand extreme environments. These assemblies support the electromechanical needs of military vehicles, computer systems, and high-tech weapons. Panel assemblies and cable and wire harnesses are some of the most common electromechanical assemblies used in this industry.
Electromechanical assemblies for industrial equipment applications must be robust and durable enough to operate under harsh conditions. Common electromechanical assemblies in heavy industrial equipment include custom cable assemblies, wire harnesses, and box builds.
Contract Manufacturing of Electromechanical Assemblies
Since electromechanical assemblies involve a large number of delicate components that must be arranged with skill and precision, many businesses choose to outsource their assemblies. A contract manufacturer that provides electromechanical assembly services already has the facilities and expertise needed to complete these projects quickly and cost-effectively.
As a contract manufacturer, Captor Corporation specializes in precision electromechanical assemblies for many applications. No matter what your project involves, our skilled manufacturing and assembly team can create a solution for you. Partnering with us delivers many benefits, such as:
- Complete engineering and design support: Our team uses advanced software to design and engineer your assembly for more efficient production and a superior end product. We also can streamline your assembly’s production to be as cost-effective as possible.
- Document control: We offer prototyping and testing documentation, bills of material, clear product specifications, and other documents.
- Prototyping and testing: Our prototyping and testing capabilities help refine your assembly for functionality, safety, and compliance with all applicable regulations.
- Reduced engineering and manufacturing costs: Reduce overall engineering and manufacturing costs by working with a single skilled service provider.
Build-to-Print Electromechanical Assemblies
Build-to-print contract manufacturing is the process of building assemblies according to a client’s instructions. During this type of contract manufacturing, the client provides completed design drawings containing exact specifications and material requirements. The manufacturer builds the assemblies according to these plans, with no alterations.
The benefits of build-to-print assemblies include:
- High accuracy and efficiency
- Control of your intellectual property
- Focus on your core business and let build-to-print providers handle all manufacturing
Electromechanical Assembly Services from Captor Corp.
Electromechanical assemblies are complex to manufacture and require a high degree of precision and expertise. Partnering with a trusted contract manufacturer helps companies throughout many industries obtain the high-quality assemblies they need while being able to focus on their core business.
At Captor Corp., we offer expert contract manufacturing and build-to-print services for a diverse range of industry needs. To learn more about our electromechanical assembly capabilities, contact us or request a quote today.