Product Overview

The ZWD-AFJX-4000 Auto Inlay Production Line is a groundbreaking, end-to-end automated manufacturing system engineered for the complete, uninterrupted production of high-quality contactless card inlay sheets. This integrated line consolidates all critical processes — from chip placement and antenna embedding to welding, testing, and sheet collation — into a single, seamless, and fully automated workflow. Designed to eliminate manual handling, reduce consumables, and maximize precision, it represents the pinnacle of efficiency and reliability for high-volume manufacturers of RFID, NFC, and smart card inlays.

Core Functionality & Integrated Process

The production line executes a sophisticated, continuous sequence:

1. Automated Sheet Feeding: A liftable loading cart with air-blowing separation ensures single-sheet feeding, preventing double picks. Motorized height control and sensors guarantee precise entry into the line.

2. Precision Sheet Transfer & Positioning: Suction cup modules transfer sheets between stations. Dedicated pre-positioning and correction stations use air cylinder systems and fiber optic detection to ensure each sheet is perfectly aligned before processing, with automatic double-sheet alarms.

3. Vision-Guided Chip Placement:

   • Chips are oriented via a flexible vibration tray and located by a high-precision vision system.

   • A servo-driven pick-and-place mechanism, with vacuum nozzles featuring real-time suction detection, places chips with exceptional accuracy.

   • Each chip position on the vacuum plate is protected by an independent hard block to prevent damage during subsequent welding.

4. Ultrasonic Antenna Wire Embedding:

   • Utilizes ultrasonic generators for reliable wire embedding onto a vacuum-held sheet, ensuring flatness and consistency.

   • Integrated wire breakage detection monitors the process in real-time, triggering alarms and stops if anomalies occur.

   • The software supports direct import of customer CAD files, allowing for custom antenna patterns. Speed and jumper height for each wire segment are independently adjustable.

5. Inverter Resistance Welding:

   • Employs servo-controlled inverter resistance welding tips for precise, consistent connections.

   • Features an automatic self-cleaning function where tips are polished by steel brushes and sandpaper, reducing maintenance downtime and cost.

6. In-Line Automated Testing:

   • An integrated test station automatically identifies non-functional (NG) inlays.

   • Defective sheets are marked and diverted to a reject collection station, while good sheets proceed.

7. Sheet Collating & Spot Welding:

   • Correctly positions and stacks multiple tested inlay sheets using air cylinders.

   • Uses high-efficiency ultrasonic welding to create stable pre-laminate stacks.

   • The collating sequence, sheet count per stack, and weld points are fully configurable. A thickness detection device prevents stacking errors.

8. Automatic Collection & Unloading:

   • X and Y-axis transfer units automatically collect finished pre-lam stacks.

   • Once full, stacks are transferred to a mobile unloading cart, ready for the next lamination process.

Key Features & Advantages

• True End-to-End Automation: From blank sheet feeding to finished pre-lam stack output, the entire process requires minimal operator intervention (only for bulk loading/unloading), dramatically reducing labor costs and human error.

• Consumable-Free Process: Eliminates the need for green tape or glue, significantly lowering ongoing production costs and material handling.

• Uncompromised Precision & Yield: Performing chip placement, embedding, and welding in a single pass ensures unparalleled positional accuracy of chips relative to the antenna, directly improving the final card's functional yield and performance.

• Intelligent Process Control & Monitoring:

  • Professional PC + PLC + Servo Control: Ensures perfect coordination between all stations for smooth, high-speed cyclic operation with zero inter-station downtime.

  • Comprehensive Sensing: Includes double-sheet detection, vacuum pick-up monitoring, wire breakage detection, and thickness verification, ensuring process integrity.

• High Flexibility & Customization: Supports custom antenna graphics via CAD import and allows for independent parameter adjustment at most stations. The line's modular design supports upgrades and customization for different products.

• Compact & Robust Design: Integrates a complex production line into a space-efficient footprint (4850x340x225 cm), built for 24/7 stable operation.

Technical Specifications

Applications

This production line is the ideal solution for manufacturers of:

• RFID Inlays & Tags for inventory, logistics, and retail.

• Contactless Smart Card Inlays for payment, access control, and identification.

• NFC Antenna Modules for consumer electronics and IoT devices.

• High-Security Document Inlays for e-passports and national IDs.

Why Choose the ZWD-AFJX-4000?

For any manufacturer serious about scale, quality, and cost-efficiency in inlay production, the ZWD-AFJX-4000 is a transformative investment. It replaces multiple standalone machines and manual assembly stages with a single, synchronized, and intelligent production line. By guaranteeing accuracy through integrated processing and eliminating consumables, it not only boosts throughput but also significantly improves product consistency and reduces total cost of ownership.