Solving Scale-Up Challenges: SIPU Delivers Dual-Channel, Fully Automated Ignition Coil Assembly Line

SIPU has successfully commissioned its first fully automated, dual-channel ignition coil assembly line at a client’s facility. This line breaks through the industry bottleneck of efficiently and precisely assembling multi-coil components, marking a key advancement in SIPU’s capabilities for heavy-duty precision automation integration.

1. Industry Insight: The Critical Role of Ignition Coils

In the automotive industry, the Ignition Coil acts as the “pacemaker” for engines. It transforms low voltage into over tens of thousands of volts. The Winding Consistency and insulation performance are critical to engine efficiency. Facing surging demands for capacity and quality, manufacturers now require a complete Turnkey Production Line that automates the entire process from pin insertion to final assembly, rather than just standalone machines.

Primary Coil

Primary&Secondary Coil

Ignition Coil

2. Challenge & Innovation: The Dual-Channel Converging Layout

The core challenge was the product architecture: one assembly contains two distinct coils, making single-line production inefficient. SIPU’s innovative “Dual-Channel Converging Layout” is a game-changer:
• Parallel Processing: Customized CNC Winding Machines operate simultaneously on both lines.
• Synchronized Workflow: Pin insertion, winding, and soldering occur in parallel on both sides.
• Central Convergence: A robotic arm performs precise Auto Assembly where the two lines meet.
This design maximizes floor space utilization and reduces cycle time by over 40%.

3. Breakthrough: Expanding from “Precision” to “Heavy-Duty” Integration

An expert in precision micro-coils, SIPU adapted to handle heavy workpieces by developing a robust material handling system:
• Heavy-Duty Handling: Reinforced conveyors and large-scale trays ensure stable transport.
• Complex Integration: The integration of 10+ automation units thoroughly validated SIPU’s proprietary PLC control systems and cross-departmental collaboration, achieving a stable First Pass Yield of over 99.5%.

4. Delivery & Commitment: Customer Validation

Leveraging strong R&D Capability, SIPU completed the entire project from design to delivery on schedule. The client highly praised the line’s high speed and remarkable stability. This delivery proves SIPU’s evolution into a reliable Automation Solution Provider.

5.FAQ

Q1: Can this line produce different types of ignition coils?

A1: Yes. The main frame is dedicated, but winding fixtures and soldering jigs are modular. Switching these tooling parts and corresponding programs allows adaptation to various models.

Q2: How do you ensure welding quality?

A2: We integrate a high-precision automatic soldering station with flux control. An optional CCD vision inspection system can be added pre-assembly to check for cold solder or bridging.

Q3: Does SIPU provide installation services?

A3: Absolutely. For integrated lines, we provide global on-site installation. Our engineers will handle setup, debugging, and training at your facility to ensure a smooth launch.

Q4: What is the expected output and ROI timeline?

A4: The exact ROI period depends on your volume and labor savings, but clients typically project full return on investment within 18-24 months.

Facing complex assembly challenges or seeking to upgrade your existing line? SIPU offers comprehensive customization from single machines to turnkey lines.
Contact us today to request the detailed case study or schedule a technical consultation for your next project.