• What is an Electromechanical Part?
• What is an Electromechanical Assembly?
• Key Components in Electromechanical Assemblies
• Electromechanical Parts Compared With Other Types of Systems
• What is the Electromechanical Assembly Process?
• What are the Biggest Challenges in Electromechanical Assembly?
• What are Typical Applications for Electromechanical Assembly?
• Electromechanical Assembly in Contract Manufacturing
• Komaspec’s Electromechanical Assembly Services

Electromechanical assemblies are everywhere in modern manufacturing, and are crucial to the most basic function of most equipment and products. The complexity of assembling and designing them is daunting – the ability to combine both electrical and mechanical parts in a reliable and consistent way is a definite skill.

Because of this complexity, many equipment manufacturers who need electromechanical assemblies to incorporate them into their equipment will have them designed and manufactured by subcontracting their requirements to specialized companies that can supply these assemblies that meet their specifications.

Electromechanical parts are integral components that merge electrical and mechanical functionalities that are found in a wide array of everyday devices. Any device combining both electrical and mechanical parts can be called electro-mechanical. They are used in a wide variety of household, commercial, and industrial equipment because of their key function: receiving electrical signals or inputs and then exerting physical force or conducting work. An electrical motor is one such device that receives electrical energy which it converts into rotational mechanical motion.

Fig.1: Electromechanical Motor

An electromechanical assembly are sub-assemblies which combine electrical and mechanical components to create complex functional systems. This process involves carefully integrating parts like motors, switches, and gears, with electronic circuits ensuring that each element works in concert with others to deliver the desired functionality.

These assemblies are devices or systems where the electrical components, such as power sources, control circuits, and wiring, effectively interact with mechanical components, like moving parts and structural frameworks, resulting in a fully operational unit.

Examples of an Electromechanical Assembly

Electromechanical assembly examples are motors, fans, and switches that perform key operational functions.

• Motors convert electrical energy to mechanical energy, which is essential for motion in devices; from small precision instruments to large industrial machines.
• Fans are important for thermal regulation, maintaining optimal operating temperatures through effective heat dissipation.
• Switches are integral in control circuits which enable user interaction and system regulation, providing functionalities like start-stop control and safety cut-offs.

These components are commonly used due to their roles in motion generation, thermal management, and operational control within electromechanical systems.

Fig.2: Assembly Process at Komaspec

Electrical/Electronic Components

In electromechanical systems, electronic and electrical components play critical and distinct roles. Central to these systems are microcontrollers and processors, which serve as the command centers, managing all electronic functions with precision.

• Sensors - Sensors monitor various parameters such as temperature, pressure, flow, motion, etc. These sensors act as data gatherers, transmitting vital information back to the microcontroller for processing.
• Actuators - Actuators play a pivotal role in converting electrical signals into physical actions. They are the executors, bringing to life movements and operations through components like motors and solenoids.
• Power Supply - The power supply unit ensures a steady and reliable energy source for the electronic components at suitable voltages and currents. This can manifest in various forms, including batteries for portable systems, AC/DC converters for adaptable power input, or power regulators to maintain consistent electric power output.
• Switches and Relays - Switches and relays are instrumental in managing the electrical current's distribution and flow throughout the system.

Fig. 3: Cutaway View of an Electromechanical Part

Mechanical Systems

The mechanical components are essential in translating electrical energy into functional mechanical operations.

• Motors - Motors serve as the primary converters of electrical energy into rotational motion, acting as the primary driving force behind the system's movement.
• Gears and pulleys - Gears and pulleys play a critical role in precisely controlling and regulating movement and torque within the system. Their function is to fine-tune the mechanical output, ensuring accuracy and efficiency in the system.
• Bearings and Shafts - Bearings and shafts provide foundational support and enable controlled rotational or linear movements. They are integral to maintaining the stability and smooth operation of the mechanical parts.
• Springs and Dampers - They are used to manage forces and motions within the system. They act as cushions and shock absorbers, mitigating the impact of external forces and vibrations.
• Structural Components - The structural components, including frames, housings, and panels, constitute the physical framework of the system. These elements provide structural integrity, ensuring components are correctly aligned and securely housed.

Fig. 4: Metal Gear

Together, these electrical, electronic, and mechanical components form the backbone of electromechanical systems, each playing an integral role in ensuring that the system performs its intended functions effectively, reliably, and efficiently.

Electromechanical systems blend the best of both worlds. They have the control and precision of electronics with the physical strength and endurance of mechanics. This combination allows them to tackle a wider range of tasks, with greater flexibility and efficiency than if they were purely mechanical, purely electronic, or only based on chemical reactions.

Electromechanical systems differ from purely mechanical ones. They bring in the electronic element, allowing for more sophisticated control and diverse functions than what you'd get with just gears and levers. It's like having a smart brain controlling the muscle. This blend of electronics with mechanics opens up possibilities for automation and precision that purely mechanical systems just can't match.

When you put electromechanical systems side by side with purely electronic ones, the contrast is quite clear. Purely electronic systems are all about processing and electrical signal propagation. But electromechanical systems make things move, they apply force, and they can do physical work.

While electrochemical systems, like batteries or fuel cells, have different roles altogether. Electrochemical systems store and convert energy through chemical reactions.

The electromechanical assembly process involves designing, and assembling electronic and mechanical components, integrating them, conducting rigorous testing for functionality, and performing quality control to make the final product. The assembly process has the following steps:

• Design and Prototyping - Design and prototyping is the first phase. Engineers use Computer-Aided Design (CAD) software, crafting detailed models of the intended system. Once the design takes shape, a prototype is produced, allowing a tangible assessment of how the final product might look and operate.
• Component Sourcing and Inspection - Components are procured from various sources based on specifications. Each piece goes through a rigorous inspection to ensure it meets the accuracy, reliability, and performance criteria.
• Integration of Mechanical and Electrical Components - Components are aligned, meticulously fitted, connected, and securely fastened. Electronic components are soldered onto PCBs while mechanical parts are joined through techniques like welding or bolting. It’s a combination of different skills and techniques coming together to build something greater than the sum of its parts.
• Testing and Quality Control - Finally, the assembled system is put through its paces. Electrical connections are checked, mechanical parts are tested for their movement, and the overall functionality of the system is scrutinized. Quality control is the watchful eye over this entire process, ensuring that every detail matches the design specifications.

Each step in this process is meticulously performed so that the final electromechanical system is reliable and efficient.

Fig. 5: Electromechanical Assembly Process

Automation and Manual Aspects in the Process

Putting together electromechanical systems requires a mix of employing machines and people.  Machines and robots are great for repeated tasks like placing and soldering tiny electrical parts on circuit boards. They do this efficiently and accurately.

But, there are parts of the job where you need a human skilled worker. People are better at such jobs because they can handle delicate details and make sure everything is done just right.

So, in building electromechanical systems, machines are used for their speed and accuracy, and people are there for their ability to handle the finer details, making sure the final product is of high quality and reliability.

Here are some challenges in manufacturing electromechanical assemblies:

• Multiple types of parts, materials, and processes have to be placed together in the same assembly. These may be plastic, aluminum, cables, or steel parts which should all mate and fit well and operate without wear or damage to each other.
• Since these are two different types of parts: a mechanical, moving system, and the other an electrically controlled part; combining them into one unit is difficult. This has challenges for both systems like tolerance, fit, firmware, cabling, etc. that are compounded when they are merged to form a single functional unit.
• Each of these types of parts requires different expertise. For mechanical parts, you need expertise, for example, in CNC machining of bushings, shafts, and other parts. While for electrical experience in SMT production, electrical system design, and quality control and design of complex parts such as PCBAs and electrical harnesses. Electromechanical assemblies require a high level of expertise and capability in both areas, and this is difficult to find in a single manufacturer.

Fig. 6: Testing Electronics During the Assembly Phase

Electromechanical assemblies are at the heart of most industries, as actuators, pumps, fans, motors, and other typical electromechanical parts are the core building blocks of most equipment and electrical products we use on any given day. Here are some electromechanical assemblies used in various products:

Home Appliances

• Electrical Switches
• Electrical cooling systems
• Dispensing systems
• Cooling fans

Mechatronics

• Part grippers
• Electrical motors
• Linear actuators
• Solenoids

Automotive Industry

• Electric Power Steering Systems
• Anti-Lock Braking Systems (ABS)
• Power Windows

Aviation Industry

• Fly-By-Wire Controls
• Moving Flight Control Surfaces
• Aircraft Landing Gear Systems

Industrial Sector

• Assembly Line Robots
• Automated Material Handling Systems
• Electrical pumps
• Packaging Systems

Contract manufacturers play a pivotal role, in electromechanical equipment assembly, serving as the backbone for companies looking to bring complex electronic and mechanical products to market.

The contract manufacturers specialize in producing electromechanical assemblies on behalf of other companies, often providing not just manufacturing services, but also valuable assistance in design, prototyping, and testing.

This partnership allows original equipment manufacturers (OEMs) to leverage the expertise, advanced technology, and economies of scale of contract manufacturers. It's particularly beneficial for companies without the in-house capabilities or resources to handle the intricate processes of electromechanical assembly.

By outsourcing electromechanical assembly to contract manufacturers your company can focus on core competencies, such as research and development or marketing, while leaving the specialized task of manufacturing to the others.

Outsourcing can significantly reduce your capital expenditure, as you won’t have to invest heavily in manufacturing infrastructure and technology. This approach also offers flexibility and scalability, enabling your company to ramp up or down production based on market demand without the burden of maintaining a manufacturing facility for electromechanical assemblies.

If your company manufactures electromechanical equipment, then check out Komaspec. We have more than fifteen units of experience in making complex electromechanical assemblies and can help you from design for manufacturing and troubleshooting, to prototyping to mass production of your finished product. Komaspec has the know-how and technology to make your project a success.

Want to learn more or get in touch? Just head to our website to see how we can help you with your assembly and manufacturing needs. Reach out to a sales engineer at Komaspec or its sister company Komacut today!