custom relay assembly line
Rotary vs Modular Layout | Yangning
Modular vs. Rotary Indexing Relay Assembly Systems: Which Fits Your Factory Layout?
Rotary cam dial systems use intermittent cam indexing to execute all assembly operations synchronously on a circular platen. Modular pallet transfer relay lines use independent station modules linked by pallet conveyance for multi-variant production. The two architectures differ in footprint, cycle speed, tooling rigidity and product changeover time for relay manufacturing.
Rotary Cam Dial: Footprint, Speed, Rigid Tooling
Cam-driven rotary indexers run all stations simultaneously during dwell phases. Standard 8-station relay dial footprint is 2.2 m × 2.2 m. Index repeatability reaches ±0.01 mm. Fixed dedicated tooling delivers stable cycle time from 0.7 s to 2.5 s per finished relay.
Pallet Transfer Modular Line: Multi-model Changeover & Buffer
- Pallet transfer modular lines separate assembly, vision inspection and electrical test into independent modules. Line footprint scales linearly with station count, typical range 6 m × 1.6 m for 8 stations.
- Pallet carriers carry product through sequential stations. Buffers can be inserted between modules to isolate station downtime. Changeover time drops to 0.5–2 hours via quick-release fixture sets, suitable for mixed automotive relay SKUs.
ROI Calculation Based On Production Volume Tiers
Core formula:
Payback Period = Total System Capex ÷ Annual Net Savings
Annual Net Savings = Labor reduction + scrap reduction + throughput revenue gain – annual maintenance cost
- Volume >1,000,000 pcs/yr: Rotary dial yields lower per-unit cost, faster payback
- Volume 200k–1M pcs/yr with 3+ relay variants: Modular pallet line reduces re-tooling expense
- Volume <200k pcs/yr: Hybrid cell configuration is recommended
