Design & Automation Solutions (DAS) worked in close collaboration with Mitsubishi Electric and IMI Norgren to deliver a fully automated lead-frame feeding and cropping system for Batten & Allen, supporting high-volume electrical component production.
The system was developed to supply precisely cropped lead-frames ahead of an over-moulding process, forming a critical upstream operation for relay base components manufactured for an international end customer. The project focused on improving throughput, accuracy and energy efficiency, while reducing manual intervention and changeover time.
Client: Batten & Allen
Sector: Electronics Manufacturing
Technology Partners: Mitsubishi Electric and IMI Norgren
Machine Builder & Integrator: Design & Automation Solutions (DAS)
Deliver consistent, high-precision lead-frame feeding and cropping at speed with key features:
- High-speed, automated feeding and cropping of reeled lead-frames
- Tight dimensional tolerances to support downstream over-moulding quality
- Multi-axis synchronised motion for precise feed and crop control
- Rapid changeovers between lead-frame formats
- Reduced energy consumption compared to traditional pneumatic systems
- Seamless integration with existing production equipment
DAS designed and manufactured a compact automated work cell incorporating servo-driven feed and crop mechanisms, controlled via Mitsubishi Electric MELSEC iQ-F PLC technology with multi-axis synchronised motion.
One servo axis controls the continuous feeding of the stamped strip, while a second delivers up to 6000N of force to the cropping tool. A non-contact loop control system maintains constant web tension from the decoiler, and a multi-roller strip straightener ensures optimal material flatness prior to cropping.
The use of electric actuators, combined with advanced motion control, delivers accurate and repeatable positioning while reducing overall energy consumption.
- Throughput: Up to 700–900+ lead-frames per hour (application dependent)
- Accuracy: ±10 micron dimensional tolerance
- Material handling: Reeled lead-frames up to 40mm wide
- Component length: Cropping capability up to 250mm
- Actuation: Servo-driven feed and high-force cropping axis (6000N)
- Loop management: Non-contact web tension control
- Tooling: Quick-change tooling with high positional repeatability
- HMI: Touchscreen interface with diagnostics and fault logging
The automated system has delivered a significant step-change in productivity for Batten & Allen, increasing throughput, improving quality control and reducing manual handling. Faster changeovers and a modular design provide long-term flexibility, while the shift to electrically driven actuation supports lower energy consumption and a more sustainable production process.
The project highlights the strength of collaboration between DAS and Mitsubishi Electric, combining machine design expertise with advanced motion and control technology to unlock new efficiencies in high-volume electronics manufacturing
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3.5kN Pneumatic Assembly Press
Selector Switch for Different Product Variants
Pressure Gauge to Adjust Insertion Force
Client Tooling and Components
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Automated Torquing Machine
Torquing Machine Operator Interface
Load Cell Calibration Fixture
Fixture & Component Ready for Loading
Fixture in Position & Tool Guide
Drive Motor & Load Cell
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Operator loading the LEDs
LED before and after
Transfer mechanism, chute & carousel
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No 10 Staple
No 10 Staple Packing Line
No 10 Staple Packing Integration
