Electromechanical assemblies are widely employed in electrical and electronic systems, with different electromechanical components and subassemblies to perform diverse functions.

In this article, we will introduce electromechanical assembly, including different variants and primary methods, and how you can achieve the best one for your specific demands.

What is Electromechanical Assembly?

Electromechanical assembly refers to any assemblies or subassemblies of electrical and mechanical components. These assemblies can change according to the application of the final product. To make electromechanical assembly, there are different techniques to apply, including surface mounting, soldering, through-hole mounting, and circuit layout.

Electromechanical assembly seems quite complex that only experienced specialists can make it by using detailed blueprints and with high degree of accuracy.

What are The Benefits of Electromechanical Assemblies?

Partnering with an experienced electromechanical assembly provider offers numerous advantages that can streamline production and optimize your business processes. The key benefits include:

  • Comprehensive engineering support: In addition to physically constructing the assemblies, their engineering teams provide end-to-end design services, including support with design, testing, and improvements.
  • Detailed documentation control: As professional manufacturers with turnkey solutions, they assist with complete documentation, like bills of materials, prototyping/testing records, and precise product specifications.
  • Prototyping and testing capabilities: Support for prototyping and testing enables early validation of electromechanical assembly products, ensuring compliance, safety, and optimal materials/configurations before manufacturing begins.
  • Cost savings on production: Partnering with an electromechanical contract manufacturer allows you to reduce overall production costs for component sourcing, facility/labor/equipment costs, and leveraging established supply chain networks.

What are The Benefits of Electromechanical Assemblies?

What Types of Electromechanical Assembly?

The specific purpose of an electromechanical assembly will determine the components used. There is a wide range of common applications, and below are typical examples of electromechanical assembly:

Switch and Sensor Assemblies

Sensor and switch assemblies are used in many controlling systems. They detect external stimuli such as motion, light, heat, or sound and convert them into electrical signals.

A sensor assembly often contains several elements, including:

  • Sensing elements – to detect the external stimuli
  • Transmitters – to transport the data collected
  • Connection heads – to link the transmitters to the sensor wires
  • Housings – to protect the sensors

Switches can allow or stop the flow of current, including the typical components:

  • Contacts – to monitor the flow of current to and from the switch
  • Switching mechanism – to control the device with a push button or toggle device
  • Wiring harness – to keep the switch in place

Panel Assemblies

Electromechanical assemblies are often set up in panels to facilitate controlling the distribution of electrical power to other circuits. To create these panels, follow the below guide:

  • Place components correctly on the back panel
  • Make holes for the components through sawing or punching
  • Drill holes to mount the hardware
  • Wire the panel

DIN Rail Assemblies

These assemblies are sometimes named mounting assemblies as they aim to mount several components as part of an electromechanical assembly. We identify the configuration of a DIN rail through the subassemblies and components that have been consumed.

Mounting rails in box builds help simplify mounting and streamline assembly while ensuring enough space and stability for fragile components.

Power Supply Assemblies

Power supplies take a current and turn it into a suitable voltage and format for one or several electric loads, then they manage to generate power. They can either be combined with products or work as standalone devices.

The standard components contributing to power supply assemblies include:

  • Transformer – to adjust the voltage as it comes in
  • Rectifier – to convert the current from AC to DC
  • Filter – to smooth out the DC output waves after rectification
  • Regulator – to decrease ripple voltages left from the filter
  • Housing – to protect the components

Transformer Assemblies

Transformers are placed between circuits to deliver electrical energy. Each circuit needs a specific voltage, and a transformer converts the voltages between one or more circuits to make them work as part of one system.

Typical components in a transformer assembly include:

  • Primary and secondary windings
  • Laminated core
  • Insulating materials
  • Application-specific tanks/accessories, including oil conservators, cooling tubes, and breathers.

Cable and Harness Assemblies

These types of electromechanical assemblies are constructed of wires and cables designed to transmit electrical signals and/or power. Cable and harness assemblies often consist of:

  • Wires and cables – to deliver the signals or power
  • Relays – to automatically turn the power on and off depending on high-amperage circuits
  • Fuses – to reduce damage from any power surges to the product
  • Connectors – to connect the components and wires to the device
  • Insulators – to protect the system from any electrical components touching each other or anything else
  • Ties – to secure the assembly to the system

Relay Assemblies

Electromechanical relays are switching components used in many electrical machines today to monitor high-power electrical devices. They can control a circuit with a low-power signal or multiple circuits controlled by a single signal.

Electromechanical relays contain electronic parts, allowing a wide range of different applications. They are most commonly used in the general aviation, aerospace, and wireless technology industries.

Relay Assemblies

What are The Electromechanical Assembly Methods?

Electromechanical assembly methods integrate electrical and mechanical components into functional systems and devices. Below are some of them:

  • Box build: The box build assembly aims to create the foundation of many electronic devices, from computers to medical equipment. These assemblies are the ideal solution for the electronics to work as intended.
  • Hand soldering: Hand soldering is a versatile solution to generate and maintain electronic connections. Although there are now automatic soldering methods, hand soldering is an indispensable skill in terms of custom, small-scale, and precision tasks.
  • Point-to-point wiring: This electromechanical assembly method connects electronic components in a microphone, preamp, amplifier, or any other piece of equipment. In this method, each component is directly soldered to a solder lug, tube pin, or jack. This traditional method of connecting solders is now largely replaced by printed circuit boards that use conductive traces instead of wiring.
  • Wave solder: This bulk soldering process allows the manufacture of many circuit boards in a short period by transferring each circuit board over a pan of molten solder. A pump in the pan generates a “wave” of solder to wash over the board and solder the components to the board.
  • Wire wrapping: an electronic component assembly technique that involves wiring telephone crossbar switches. It is then adapted to create electronic circuit boards. Electronic components mounted on an insulating board are interconnected by lengths of insulated wire run between their terminals. The connections are created by wrapping turns of uninsulated sections of the wire around a socket pin or a component lead.

What are The Electromechanical Assembly Methods?


Applications of Electromechanical Assemblies in Specific Industries

We can see electromechanical assemblies in various electrical and electronic devices and systems, including computer interfaces, displays, control systems, fan and blower systems, and power distribution networks.

Let’s check out the industries that use electromechanical assemblies most in their operations:

  • Aerospace: The aerospace industry requires reliable, compact, and high-precision electromechanical assemblies. The layouts must be custom-designed to facilitate unique features of aircraft systems.
  • Automotive: In the automotive industry, electromechanical assemblies are required to be highly reliable and long-operating. They must also provide flexibility in design to suit different automotive system requirements.
  • Agricultural: Tractors, sprayers, and combines need switches, sensors, and other custom-designed electromechanical assemblies to operate effectively and efficiently.
  • Heavy equipment: Heavy equipment and vehicles often perform in harsh environments, mainly depending on reliable custom cable assemblies, box builds, and wire harnesses.
  • Military: To serve the sophisticated and interconnected requirements of electronic military devices, vehicles, computer systems, and weapons, military-grade electromechanical assemblies must be able to tolerate extreme conditions.
  • Fire protection: Hospitals, institutions, and other public and private spaces need high-performance electromechanical assemblies for their element of fire protection and suppression systems.
  • Medical: Electromechanical assemblies can help promote sustainable energy usage, enhance motion control precision, and construct powerful yet compact tools. The assemblies are applied a lot in delivery systems, cardiac defibrillators, IV pumps, MRI machines, and internet-connected medication monitoring systems.

Applications of Electromechanical Assemblies in Specific Industries

Consult Component Assemblies Service of Fischer ASIA

Fischer ASIA offers a one-stop service for manual component assemblies across electronic and mechanical products. By combining metal components with other materials like plastics, die-casting, and electronic parts, we can create turnkey assembled products ready for end-use applications. Our cross-functional expertise can help customers merge diverse parts into unified assemblies to meet their performance requirements.

We adhere to LEAN principles to maximize productivity while maintaining stringent quality standards. Rigorous quality checkpoints throughout our assembly lines help us ensure zero defects and deliver flawless components meeting all expected quality metrics. Contact Fischer ASIA for detailed consultants on component assembly services now.