Applications: Pressure/temperature/level sensors, vibration sensors, automotive electronic sensors, MEMS micro/precision sensors, outdoor/waterproof sensors, etc.; various connectors, capacitors, micro-switches etc.
Equipment solutions: All of these require two component potting machines for processing, including manual potting machines, automatic potting machines, micro-potting machines, vacuum potting machines etc.
Sensors are widely used in automotive and industrial equipment, where operating environments are complex and often present challenges such as high temperatures, high pressure, and corrosion. The core application of potting machines in sensor connectors is to achieve precise potting and protective sealing. Through automated metering, mixing, dispensing, and curing control, they ensure that sensor connectors maintain waterproofing, dust proofing, insulation, shock resistance, and temperature resistance in harsh environments. These machines are critical process equipment in fields such as automotive electronics, industrial sensing, and new energy storage.
In automotive manufacturing, two-component (AB) dispensing machines are commonly used to seal automotive sensors. Components such as headlights, tire pressure monitoring systems (TPMS), and oil pressure sensors require high-temperature resistance and corrosion resistance to ensure driving safety. By precisely controlling the adhesive mix ratio and dispensing volume, these machines ensure a uniform layer of protective adhesive covers the sensor surface, thereby providing waterproofing, shock resistance, and corrosion protection to extend the sensor’s service life. Additionally, in automotive manufacturing, some applications require sealing and potting of sensor terminals to ensure stable operation under operating conditions ranging from -40°C to 125°C. For micro MEMS sensors, micro-dosing is required, combined with vision-guided positioning, to achieve micro-encapsulation in extremely small spaces. For high-reliability connectors (automotive/aerospace) that require full automation, large-scale production lines with high efficiency and output demand fully automated vacuum potting machines and vacuum potting line solution , which can perform vacuum degassing and fill all areas without dead zones.
Sensors have very high requirements for potting machine :
No air bubbles are allowed, as they would affect accuracy and pressure resistance; The adhesive volume must be precise and consistent, with no overflow onto probes or pins; Waterproofing, shock resistance, temperature resistance, oil resistance, corrosion resistance, and moisture resistance.
Common adhesives: Epoxy resin, silicone gel/silicone rubber, polyurethane etc.
Functions:
Sealing and waterproofing: Achieve IP67/IP68 ratings to prevent the ingress of moisture, oil, and dust.
Shockproof and drop-resistant: Secures internal chips, coils, and pins after curing, providing vibration resistance.
Insulation and protection: Prevents short circuits, electrical leakage, and signal interference.
Thermal conductivity and heat dissipation: Conducts heat away from the sensor interior to extend service life.
Structural reinforcement: Protects fragile MEMS, chips, and strain gauges.
Advantages of SECOND dispensing machines
There are numerous types of sensors, including pressure, angle, position, and humidity sensors. While each product has different potting requirements, they share common characteristics: limited internal space; high demands for precise adhesive control; and extremely low tolerance for air bubbles. This requires potting machines to perform exceptionally well across multiple parameters. Leveraging 20 years of industry experience and leading technology in the Chinese market,Second Intelligent has developed mature potting line solutions.
Precision metering system
During the design phase, Second intelligent ’s engineers use data such as adhesive ratios and dispensing speeds as key criteria for selecting the appropriate metering pumps. Precise control of micro-dispensing is fundamental to automotive sensor potting. For miniature sensors, micro-dispensing machines can measure and inject adhesive with exceptional precision.
High dispensing accuracy and precise adhesive ratio control
By utilizing high-precision metering pumps and appropriate valves, the mixing ratio of Component A (resin) and Component B (curing agent) is controlled in real time. Whether for simple 1:1 or complex 10:1 formulations, a mixing accuracy of over 99% is achieved, ensuring the final performance of the adhesive from the source.
Vacuum degassing
Equipped with a vacuum pump, the system continuously removes air before mixing or dispensing, completely eliminating the risk of air bubbles.
XYZ 3D platform + programmable paths
Based on CNC programming, dispensing paths, volume, and speed can all be precisely set. Whether for circular, square, or irregularly shaped sensors, uniform dispensing is achieved. Through visual trajectory programming, the system can handle complex sensor structures and prevent localized adhesive buildup.
For sensors with complex paths, CCD vision or 3D vision can be selected for real-time inspection to ensure uniform adhesive coverage with no omissions, buildup, or stringing.
Automation for high efficiency
Enables automated assembly line operations, allowing a single operator to manage multiple machines. This significantly boosts production efficiency while freeing up labor and ensuring continuous, stable output 24/7.
Stability and consistency
From high-viscosity adhesives to AB adhesives, SECOND equipment maintains consistent dispensing performance even during long-term operation, minimizing batch-to-batch variations.
Improving product yield
All process parameters (mixing ratios, flow rates, timing, etc.) are recorded and traceable.
Second Intelligent has strong solution and technical service capabilities, and will provide customized glue filling solutions to customers based on their adhesive characteristics, production process requirements, production capacity requirements, factory space, and other comprehensive factors. At the same time, in the global market, we will provide comprehensive solutions and technical support services to global customers through distributors, agents, and our headquarters’ 50+technical team.
