Tongchuan TCR Automated Conveyor Line: 3 Efficient Solutions for Electronics Assembly

Hey, the bosses and engineers of electronic factories, are you often confused by these problems? 👉 assembly line parts piled up into the mountains, workers are busy with the old wrong; 👉 product model change will have to stop work to change the production line, delayed orders can be anxious to death; 👉 would like to automation and fear of expensive equipment, difficult to operate, and finally become a pendulum ... do not panic! Today we will nagTongchuan TCR automated conveying lineSee how it solves the "big problem" of electronic assembly with three moves!

🔍 First, the pain points of the electronic assembly line: the traditional assembly line for why always "neck"?

(in conjunction with web pages 1 and 3)
Electronic assembly lines are most commonlyleather belt linerespond in singingdoubled speed chainTwo kinds. Belt lines are cheap but faulty:

  • ❌ Poor transfer accuracy, parts tend to run out of place.
  • ❌ Load of more than 250kg "can not carry", precision circuit boards do not dare to put
  • ❌ Dust strikes when there's too much dust, and cleaning can be exhausting!

The multiplier chain is solid, but the traditional scheme is also hard:

  • 💸your (name)! A line can cost hundreds of thousands of dollars.
  • ⚙️slow-witted! It takes half a day to change the model number.
  • 📉data black box! Why is the yield rate low? It's all up to the master to guess...

​Talking Human Edition: It's like transporting a refrigerator on a bicycle - it either falls apart or you die of exhaustion! (Webpage 3 data reality check: average downtime for traditional wire body changeover)4 hoursYield rate fluctuates more than15%)

The "three axes" of Tongchuan TCR: precision, flexibility, and thinking!

1️⃣ First Axe: Harmonic Reducer Black Technology ➕ Multiplier Chain = ⚡ Millimetre Precision Positioning

(Core from page 7, page 11)
Tongchuan's speciality isharmonic reducer (mechanical engineering)(self-developed 3D curved tooth shaping technology), stuff it into the conveyor line motor, and just turn it on:

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Conventional motor → large jitter → positioning error ±2mm
Tongchuan TCR motor → harmonic deceleration speed control → error ≤±0.1mm!  


To give a chestnut 🌰: a shenzhen mobile phone factory paste camera module, the past artificial alignment old crooked. After the TCR lineJacking mechanism + photoelectric sensingAuto-calibrated position, placement failure rate reduced from 8% to 0.3%!


2️⃣ Second Axe: Modular Design = 🧩 Changing products is like changing Lego!


(drawing on pages 6 and 9)

Shen Xiaolong (General Manager of Tongchuan Technology) said, "The core of flexible production is to adapt equipment to people, not people to equipment!" The TCR conveyor line did it:


    

  • Standardised interfaces for tooling boards, change of model only requiredChanging the magnetic suction module(5 minutes to finish)
    • 

  • Free splicing of roller section/belt section, production line layout can be changed by dragging and dropping with the app.
    • 

  • Support"Adaptation while producing", without having to stop the whole line (a Dongguan headset factory measured to save 37% change line time)
    • 



3️⃣ Axe 3: WMS + WCS Dual System = 📊 Data-Driven Decision Making


(technology from page 6, page 8)

You thought it was just a conveyor belt? No! It's got the most powerful brain in the world:


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WCS control system (Web 8 case) → real-time regulation of conveying speed, collision prevention
WMS management system → tracking of each work order:
- Material loss (such as solder paste more than 5 grams immediately alarm)
- Workstation time (stuck in which link?). At a glance)
- Equipment health (bearings are going bad? 3 days in advance)  




​Boss Slap Your Thigh Moment: After using this system in a circuit board factory in Guangzhou.Material wastage cut by 22%The device is zeroed for unexpected shutdowns!






🤖 Third, the operation of the white man can handle: TCR for what "grounded"?


(Refer to page 5 and 8 for practical exercises)

Afraid of automated equipment operation complex? Tongchuan has thought about it for you!


    

  • ​Mobile App Scan Code LaunchWorkers "drop" the equipment and the corresponding product process is automatically called up.
    • 

  • ​Fault self-diagnosis: The screen says directly: "The third drum jam 👉 Press the red button to reset" (much easier than fixing a printer).
    • 

  • ​AR glasses for training: Novices wear glasses and follow the virtual arrows to become skilled in 3 days 💪.
    • 





A factory director's original words: "Previously, an engineer was invited to adjust the equipment with a monthly salary of 20,000, and now a team leader with junior high school education can manage the whole line!"






📈 Fourth, do the economic maths: is it expensive? Is it worth it?


(Data integration web page 2, web page 10)






sports event
traditional assembly line
Tongchuan TCR automation line






initial investment
200,000
500,000




retrofitting
Single ≥ 10,000
Module replacement ≤ $2000




average daily production capacity
8000 pieces
13,000 pieces ⬆️63%




Average monthly scrap losses
$47,000
18,000 ⬇️62%




​payback period​
​Approximately 14 months​
​8 months🚀








👉put the emphasis on: Don't look at the expensive to buy, use the savings! A factory in Dongguan 10 months to return to the capital, the second year to earn more1.7 million!






💡 Exclusive view: the future of the factory is "adaptability"!


(in conjunction with web page 3, web page 9)

I have observed a trend: electronic assembly is moving away from "single-issue pop-up"Turning."Small batch customisation". A production line like TCR that can be reorganised and data linked at any time is what is needed in the future! To give a scenario:




Monday produces Bluetooth headphones → Tuesday cuts smartwatches → Wednesday changes rechargeables...

The TCR line body was still in Shop A in the morning putting together the circuit, but in the afternoon it was disassembled into three sections:

One section goes to workshop B to do shell painting, two sections stay in line A to upgrade the firmware-This is real - flexible manufacturing!




Tongchuan Shen points out the essence in the interview:




"Automation isn't replacing people, it's allowing people to do more valuable things!For example, analysing data and optimising processes - this is the logic of upgrading China's smart manufacturing."






🚀 A final word of truth.


Don't be greedy on automation!The "blood vessels" of the conveyor line will be taken care of first, and then the "organs" (robotic arms/detectors) will be added step by step.The great thing about the Tongkawa TCR is this:

👉Leave the operation entrance for the white man(Mobile APP + AR training)

👉Leaves room for upgrades for the best(Compatible with ABB/KUKA robots)

👉Leaves room for the boss to make money(Doesn't it smell good with an 8-month payback?)


Next time you see parts flying around the shop floor and workers running after the assembly line, remember to yell, "Get a smart conveyor line, isn't it better than running your legs off?!" 💥

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