Revolutionizing Fuse Assembly: Ruizhi Intelligence’s Fuse Assembly Machine Redefines Precision Manufacturing
In the era of global electronic manufacturing’s relentless pursuit of miniaturization and intelligence, fuse assembly—critical for circuit protection in consumer electronics, automotive systems, and industrial equipment—has entered a new phase of automation. Ruizhi Intelligence recently unveiled its cutting-edge Fuse Assembly Machine, a revolutionary solution designed to address the complexities of micro-fuse, automotive fuse, and high-voltage fuse assembly with nanometer-level precision and adaptive flexibility. This system marks a paradigm shift from traditional manual assembly to fully automated intelligent production, setting new standards for reliability and efficiency in fuse manufacturing.
Core Technological Breakthroughs: Precision Engineering Meets Intelligent Control
Nanometer-Level Multi-Axis Assembly System
The equipment integrates a six-axis piezoelectric-driven robotic arm with high-frequency servo motors, creating a closed-loop control system for “positioning-welding-detection”:
- Ultra-Fine Torque Control: For micro-fuses requiring 0.5-1.2N·m torque and automotive fuses needing 3-5N·m, the system auto-adjusts between 16 tightening modes with ±0.01N·m accuracy. A leading electronics manufacturer reported a 98% reduction in fuse terminal looseness after implementing the system, with assembly efficiency increasing by 300%.
- Non-Contact Welding Technology: Using laser soldering with 5μm spot size control, the machine achieves void-free joints on 0402-sized micro-fuses, reducing thermal damage to the fuse element compared to traditional soldering methods. The technology ensures solder joint reliability with shear strength exceeding 50N for miniature fuses.
3D Visual Inspection & Intelligent Defect Screening
Equipped with 10K industrial cameras and laser interferometers, the system enables micron-level defect detection:
- Atomic-Level Surface Analysis: Phase-shift interferometry generates 3D topographies to identify 0.1μm-scale flaws like electrode oxidation or ceramic body cracks. In automotive fuse production, this reduces defective products from 2.3% to 0.07%.
- AI-Driven Path Optimization: Machine learning algorithms generate optimal assembly trajectories based on fuse 3D models. For complex high-voltage fuses, the path planning efficiency is 20x faster than manual programming, shortening cycle time from 60s to 22s per unit.
Modular Quick-Changeover System
The machine features plug-and-play tooling modules for rapid product switching:
- 8-Minute Process Transition: Dedicated modules cater to three fuse categories:
- Micro-fuse module: Integrates vacuum pick-and-place for 01005-sized fuses with anti-static design;
- Automotive fuse module: Includes multi-station terminal crimping and insulation testing;
- High-voltage fuse module: Equips with hermetic sealing and pressure testing units.
Hydraulic quick-locking mechanisms enable module changes in 8 minutes, a 90% improvement over traditional setups.- Smart Parameter Adaptation: The MES system auto-retrieves process recipes based on fuse specifications, with AI optimizing parameters like welding temperature and pressure using historical data, eliminating manual debugging errors.
Application Scenarios: Efficiency and Quality Revolution
Case 1: Automotive Fuse Box Assembly Line
In a major OEM’s automotive fuse production line, the traditional vs. automated solutions contrast sharply:
| Process Type | Manual Assembly (15 workers) | Ruizhi Fuse Assembly Machine (2 units) |
| Daily Output | 3,000 units | 12,000 units |
| Open Circuit Rate | 1.8% | 0.03% |
| Contact Resistance | ±5% tolerance | ±0.8% tolerance |
| Energy Consumption | 8,500kW·h/day | 3,200kW·h/day |
Notably, the system’s 12-point pressure monitoring during terminal crimping maintains a coaxiality deviation ≤0.02mm, ensuring stable electrical conductivity. This precision reduced post-assembly rework by 95%, saving the OEM $1.2 million annually.
Case 2: High-Voltage Fuse Assembly for EVs
For new energy vehicle high-voltage fuses (500V+), the machine addresses critical challenges:
- Traditional Pain Points: Manual assembly of high-voltage fuses required 15 minutes per unit, with 8% failure in dielectric strength tests due to air gaps in encapsulation.
- Automated Solution: The system uses vacuum encapsulation with 0.01mm-level gap control, combined with UV curing for epoxy resin. Assembly time per fuse is reduced to 3 minutes, and dielectric strength pass rates soared from 88% to 99.9%. A leading EV parts supplier reported annual cost savings of $800,000 from reduced material waste and rework.
Industry Impact: Pioneering Smart Manufacturing 4.0
As global demand for miniaturized fuses in IoT devices and EVs surges (expected 25% CAGR through 2027), precision fuse assembly has become a core competency. Ruizhi’s R&D director notes the machine’s OPC UA-compatible data system enables real-time traceability of critical parameters like welding temperature and pressure, fully compliant with ISO 9001 and IATF 16949 standards.
Deployed in over 200 facilities including Foxconn and Delphi, the system has cut labor costs by 70% per line and reduced floor space by 40%. Industry reports project the fuse assembly machine market will exceed $1.5 billion by 2026, with AI-integrated, high-precision systems like Ruizhi’s leading the trend toward “intelligent, flexible, and data-driven” manufacturing.
Technical Notes: The machine’s six-axis piezoelectric control technology holds a national invention patent (ZL2024XXXXXX), and its 3D vision system is certified to ISO 13849 PLd. Ruizhi will demonstrate the machine’s micro-fuse assembly capabilities at the 2025 NEPCON China exhibition, showcasing 0.01mm-level precision operations.
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