In electrical systems, fuse boards act as "guardians" of circuit safety. During overloads or short circuits, the fuses on these boards melt instantly to cut off power, preventing equipment damage or fires. However, for years, producing these critical components relied on manual labor—slow, inconsistent, and inefficient.
Automation Revolutionizes Fuse Board Production
Opto-Intel’s Non-Standard Automation Division has transformed this process. In their workshop, Xue Yongwen, an automation project manager, proudly demonstrated the company’s fully automated fuse board manufacturing system—the first of its kind in China. With a single button press, robotic arms swiftly shape metal fuses, producing a flawless fuse board in just 11 seconds.
"Previously, workers twisted fuses with pliers, relying on experience to adjust tightness. Each board took 40 seconds, with inconsistent placement on anti-static paper," Xue explained. Now, the machine operates 24/7, boosting efficiency and quality. Over 100 units have been sold in just a year, solving automation challenges for dry-type transformer manufacturers.
8 Months to Replace Imported Equipment
In August 2024, a Shaanxi-based company urgently needed a high-pressure bellows lifespan tester to replace imported equipment with long lead times. Opto-Intel’s 22-member R&D team delivered a domestically developed solution in 8 months.
"Foreign testers only ran at constant speeds, but real-world substation switches operate at millisecond speeds," said Wang Yang, the project lead. "We added an acceleration control system to simulate actual conditions. The device completes 10,000 high-speed tests in just over a day—and costs 20% less than imports."
Beyond Automation: Cutting-Edge Innovations
The division’s custom laser cutting-welding integrated equipment has broken bottlenecks in precision processing for high-end materials, tripling efficiency in automotive, electronics, and aerospace manufacturing.
Breaking Foreign Monopolies in Thermal Materials
"Critical thermal materials were once entirely imported—a tiny piece cost ¥200. We had no choice but to pay," recalled Geng Kai’ge, head of the division. To overcome this, Opto-Intel partnered with the Qinchuangyuan Innovation Promotion Center and universities like Tsinghua and Northwestern Polytechnical to develop five proprietary materials, including prefabricated AuSn lids and nano-silver thermal interface paste, slashing costs by 50% and ending foreign dominance.
Dual-Drive Strategy: Materials + AI Automation
Today, the division’s "dual-drive" model—combining thermal materials with AI-driven automation—serves over 400 clients globally.
"We’re not chasing grand narratives. We’re problem-solvers," said Geng. "If clients need fast delivery, we deliver in 8 months. If they need import replacements, we boost performance and cut costs." Moving forward, the team will integrate AI deeper into automation, expanding into integrated circuits and solar photovoltaics to fuel Xi’an’s high-end manufacturing growth.
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