The integration of mechanical, electronic, and software-based components, into a functional overall system. This includes the assembly, testing, and commissioning of complex assemblies or devices, in which electronics and mechanics are closely linked.
At TPS Elektronik, we design and build intelligent mechatronic systems that combine mechanics, electronics, sensing, software, and motion. From single electromechanical assembly modules to fully automated production lines, our team integrates actuators, drives, sensors, pneumatics, and industrial controls into robust products and turnkey equipment. Whether you need a custom mechatronic system for precision manufacturing or high-volume automation assembly, we deliver production-ready solutions with lifecycle support.
What We Deliver
Electromechanical Assemblies
- Boxed and open-frame electromechanical assemblies / electromechanical assembly services, cable sets, and safety interlocks.
- Precision mechanisms with bearings, lead screws, linear guides, and servo motor driver electronics.
Custom Automated Machines
- Concept-to-commissioning for custom automation machines / custom automated machine / custom automation machine manufacturer projects.
- Indexing and continuous motion assembly machine platforms; feeders, vision inspection, force/torque monitoring, and traceability.
- Complete assembly automation systems tailored to takt time, including automation production line / production line automation cells and end-of-line test.
Industrial Automation & Controls
- Industrial motion control systems with closed loop motion control system architectures (encoders, resolvers, load cells, piezo drive, and voice-coil stages).
- Control system and industrial automation design: PLC/IPC/edge controllers, safety PLC, industrial networking, and SCADA/MES connectivity—the best OT systems for industrial automation for your stack.
- Distributed control system vs PLC guidance (see comparison below) and integration as an industrial automation systems integrator.
Robotics & Mechatronics
- Pick-and-place, collaborative robots, AGV/AMR interfaces—automation & robotics engineering / mechatronics and robotics engineering / robotics and automated systems engineering.
- Rapid prototyping with test rigs and RC robots for proof-of-concept.
Fans, Fluids & Pneumatics
- Thermal subsystems using industrial axial fans / axial fan industrial / axial exhaust fans industrial and radial fans with smart speed control.
- Pneumatic design using air hose pipe fittings, push to connect fittings, air regulator, air dryer, vacuum filters, and check non return valve (NRV) components.
Drives & Power
- AC drive and servo systems, stepper stages, and brushed/BLDC solutions with integrated safety and energy management.
Engineering Approach
Mechatronic Design and System Integration
- Requirements → concept → architecture for mechatronic systems and control.
- Mechanical CAD, tolerance analysis, and machining precision components via our precision shop network (your partner in mechanical manufacturing / officina meccaniche).
- Electronics (power, signal, IO) and firmware for mechatronics electronic control systems.
- Sensor fusion and integrated sensor solution / integrated sensor solutions (temp, pressure, position, vibration) plus integrated sensor solution driver electronics.
Process Integration Experience
- Deep experience in process integration and electromechanical mechatronic systems: feeders, dispensers, weld heads, presses, conveyors, machine vision, and inline test.
- We also support mechatronics engineering services ranging from FMEA and risk analysis to CE/UL readiness and documentation.
Manufacturing Intelligence & Smart Factories
- Manufacturing intelligence system dashboards, OEE capture, recipe control, and traceability to enable smart manufacturing service solutions and a truly intelligent manufacturing system (see definition below).
DCS vs PLC — Which Fits Your Plant?
| Topic | PLC | DCS |
|---|---|---|
| Typical Use | Discrete machines, skids, fast motion | Large continuous process (chemicals, utilities) |
| HMI/SCADA | Flexible, modular | Deeply integrated |
| Motion | Excellent with servo/robotics | Possible, but less common |
| Scale | Machine/line | Plant-wide |
| Takeaway | Great for custom automated machines and lines | Great for centralized process control |
We implement both, and we routinely act as industrial automation system integrators / industrial automation systems integrators to connect PLC/IPC cells into higher-level SCADA/MES/ERP.
Automated Production Lines
Automated production line definition:
A sequence of stations where materials flow through automated steps—feed, process, inspect, and pack—coordinated by a control system and safety layer, with minimal human touch.
Automated production line examples:
- PCB insertion + screwdriving + dispenser + vision alignment + end-of-line test.
- Mechatronic custom automated assembly machine integrator project: press-fit gear + gear position sensor calibration + laser marking + final pack.
- Battery module line with torque traceability, leak test, and MES serialization.
Typical Mechatronics Subsystems We Integrate
- Servo motor driver + encoder + gearbox (or direct-drive).
- AC drive for pumps/fans/conveyors.
- Automated production lines with feeders, escapements, and vision.
- Pneumatic manifolds (FRL: air regulator, air dryer, filters), valves, cylinders, and push to connect fittings with check non return valve.
- Vacuum pick with vacuum filters and ejectors.
- Thermal/airflow assemblies using industrial axial fans / axial exhaust fans industrial and radial fans.
- Sensing: integrated sensor solutions such as gear position sensor, clutch position sensor, torque, TR sensor, pressure, and temperature.
- Safety: light curtains, interlocks, e-stops, PL/d ratings.
Industries & Use Cases
- Electromechanical assemblies for medical, instrumentation, and consumer devices.
- Mobility: automotive actuators, mech injection (mechatronic injection subsystems), thermal shutters and HVAC damper drives.
- Factory lines: palletizers, dispensers, inspection cells, and assembly automation lines.
- Electronics EMS: handlers, screwdriving, conformal coat, and test fixtures.
- Ventilation & HVAC modules with smart axial and radial fans.
Build & Production
- Rapid precision parts production and kitting; in-house wiring, panel build, and electromechanical assembly manufacturer capabilities.
- FAT/SAT with documented performance curves, MTBF estimates, and spare kits.
- Full lifecycle services: upgrades, retrofits, and global support.
FAQs
What is an intelligent manufacturing system (definition)?
A connected production environment where machines, sensors, and software share data to optimize quality, throughput, and maintenance—often via SCADA/MES and analytics.
How do you choose between a PLC and DCS?
Use PLC/IPC for discrete equipment and fast motion; use DCS when centralized control of complex continuous processes is needed. We often hybridize both.
Do you supply both machine and product assemblies?
Yes. We build electromechanical assemblies (the product) and custom automated machines (the equipment that makes the product).
Can you integrate pneumatics and vacuum?
Absolutely—complete FRL stations with air regulator, air dryer, vacuum filters, air hose pipe fittings, push to connect fittings, and NRVs (check non return valve).
Do you support automotive sensors and actuators?
Yes—gear position sensor, clutch position sensor, TR sensor, and automotive actuators with diagnostics and embedded control.
Get a Proposal
Share your user requirements (URD), cycle time, footprint, safety class, utilities, and any vendor standards (PLC/HMI/robot). We’ll return an architecture concept, risk & cost drivers, and a phased budget for your integrated mechatronic systems solutions—from pilot cell to full automation production line.