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HomeTips & GuidesElectromechanical Assembly: Types, Benefits, and Applications

Electromechanical Assembly: Types, Benefits, and Applications

About Electromechanical Assembly: Some machine parts require combinations of electrical and mechanical components to optimize their operations. 

So as machines, like cars, planes, and heavy equipment, advance, they are increasingly getting electromechanical assemblies to enhance their operations. 

We will analyze these electromechanical assemblies below to determine their types, benefits, and applications.

Table of Contents

What Is an Electromechanical Assembly?

An electromechanical assembly is a general term referring to any combination containing electronic and mechanical components. These components generate power or control energy flow to different distribution systems.

Most modern high-tech devices require electromechanical assemblies to function effectively.

The classic electromechanical assembly device example is a rotary converter, which can convert AC to DC and vice versa.

This device contains rotating AC and DC machines, and it can operate as a motor or generator, depending on the flow of current.

A rotary phase generator features a control panel electromechanical assembly that starts and stops the idle generator to maintain the voltage balance between the phases.

Phase imbalances can damage the three-phase equipment, so this electromechanical assembly is critical to safeguard your expensive machines.

Types of Electromechanical Assemblies

Electromechanical assemblies come in these five types.

DIN Rail Assemblies

DIN is an acronym for Deutsche Institut fur Normung, the German Institute of Standards. These rail assemblies are metal strips built for attaching electrical and industrial control mechanisms, such as:

  • Actuators
  • Solenoids
  • Wiring/cable systems
  • Terminal blocks
Electrical and control devices mounted on a DIN rail

Electrical and control devices mounted on a DIN rail

Therefore, DIN rail assemblies help mount other electromechanical components, making them part of the assembly.

The rails have become popular due to their superb physical component support properties, and the DIN rail configuration depends on the parts and subassemblies used.

Switch and Sensor Assemblies

Switches and sensors are typical in most control systems but have different functions. The former permits or halts electric current flow through a circuit system and has three primary components.

These are the wiring harness, contacts, and switching mechanism.

On the other hand, sensors detect external stimuli, such as heat, moisture, sound, motion, and light, then convert them to electrical signals to provide the required input to the circuit.

This assembly has the following four primary components.

  • Sensing element
  • Transmitter
  • Connection head
  • Body or housing
A motion sensor

A motion sensor

Transformer Assemblies

Different circuits in the same system might have to operate at different voltages, and transformers help convert voltage levels between them.

These devices can step up or down voltages when integrated between circuits, and they perform this function without creating a physical or metallic connection between the two.

Transformers have the following components.

  • Laminated core
  • Primary windings
  • Secondary windings
  • Insulating materials
  • Application-specific accessories, such as cooling tubes and oil conservators
The simple design of an electric transformer

The simple design of an electric transformer

These devices operate on the law of induction, where the voltage induced in each winding is proportional to the number of windings.

Wiring Harness Assemblies

Wire harnesses are the transmission lines for electrical power or communication/sensor signals from source to destination. They comprise the following components.

  • Wires, conductors, or cables for channeling the power/signals
  • Connectors for attaching the wires to components
  • Insulators for safeguarding the conductors from touching each other, having ground faults, or anything else that can disrupt electrical current flow
  • Fuses for protecting the system from surges and other electrical faults
  • Relays for switching high electrical current circuits
  • Ties for securing the harness to the system
An automotive wiring harness

An automotive wiring harness

Power Supply Assemblies

These assemblies convert the electrical current input into a suitable voltage and format (AC or DC) to power one or more circuit loads. They usually consist of the following components.

  • Transformer for stepping up or down the incoming voltage to a suitable level
  • Rectifier for converting AC to DC
  • Filter for smoothening the DC output from the rectifier
  • Regulator for eliminating ripple voltages left after filtration
  • Case or housing to cover and protect the four components above
A computer’s power supply unit

A computer’s power supply unit


Panels are housings that host the electromechanical assemblies to simplify electrical power distribution to other connected circuits. Assembling them requires the following steps.

  • Precise hardware positioning on the back panel
  • Drilling holes for component mounting
  • Panel wiring
A technician adjusting switches on an electrical panel

A technician adjusting switches on an electrical panel

Advantages of Electromechanical Assemblies

Prototyping and Testing

Electromechanical assemblies allow technicians or engineers to test and evaluate product features, manufacturing steps, and user experiences before the item goes into full-scale production.

This prototyping before mass production enables product feature fine-tuning to achieve the best results and efficiency.

Reduced Engineering and Manufacturing Costs

Prototyping and fine-tuning before mass production cuts engineering and manufacturing costs significantly.

Without it, you might have to redo the designs after bringing a huge batch of products to market, which is expensive.

An electro-mechanic working on a diesel generator

An electro-mechanic working on a diesel generator

Design and Engineering Processes Support

Electromechanical assembly’s multiple engineering platform capabilities fully support design and engineering processes. So, you can integrate designs via software or databases to customize the product.

As for engineering, most manufacturers have dedicated assembly cells that they can interchange to accommodate new platforms or production changes.

Detailed Document Control

Several engineering platforms enable engineers to create detailed documentation on product specifications, BOM, prototyping, testing, etc.

Applications of Electromechanical Assemblies

Electromechanical assemblies are typical in computers, control systems, power distribution networks, etc., which you can find in these industrial applications.

  • Aerospace industry
  • Agricultural equipment
  • Automotive industry
  • Fire protection
  • Heavy equipment
  • Military

Wrap Up

Electromechanical assemblies have become critical components in modern-day devices and machines due to the benefits described above. 

But most importantly, they cut engineering and manufacturing costs and enable prototyping and testing. 

This combination simplifies the engineering costs, refines the product before mass production, and makes the final product cheaper. 

So, you’ll end up with a high-quality item that meets its application requirements at a competitive price. 

That’s it for this article. Share your thoughts about electromechanical assemblies in the comments below.

Hi I am Christa, sales manager of Cloom.

I have extensive expertise and experience in wiring harnesses and I believe I can help you.

And we have a very professional technical team who can clearly understand the customer’s needs and give professional suggestions and solutions after receiving the drawings.

If you also have wiring harness needs, please send me the drawing so that we can give you our quote and start our business.

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