A small-scale domestic air conditioner assembly production line
A small-scale domestic air conditioner assembly line is designed to efficiently produce compact air conditioning units. It integrates various processes, including component preparation, processing, assembly, refrigerant charging, and comprehensive performance testing. The line ensures each unit meets strict quality standards through meticulous assembly procedures and rigorous testing protocols, covering aspects like electrical safety, noise levels, and cooling/heating performance. This streamlined production approach guarantees the delivery of reliable and high-quality domestic air conditioners to meet consumer needs.
Description of a Small-Scale Domestic Air Conditioner Assembly Production Line
A small-scale domestic air conditioner assembly production line is a specialized production line used for manufacturing small domestic air conditioners. It is mainly responsible for assembling various components of the air conditioner into a complete product and conducting performance tests. The production line typically consists of the following main parts:
- Raw Materials and Components Preparation: Purchase and inspect various raw materials and components, such as compressors, heat exchangers, motors, and electrical control components.
- Component Processing: Perform processes such as stamping, bending, injection molding, welding, grinding, and painting on metal and plastic components.
- Assembly: Install core components such as compressors, heat exchangers, and motors into the indoor and outdoor units of the air conditioner, and connect the pipes, wires, and control panels.
- Vacuum Extraction and Refrigerant Charging: Before sealing the system, use a vacuum pump to extract air and then charge the appropriate amount of refrigerant.
- Performance Testing: Conduct cooling and heating performance tests on the assembled air conditioners, and check electrical safety and noise levels.
- Packaging and Warehousing: Package the qualified air conditioners and store them in the warehouse for shipment.
Assembly Process Table
| Process | Content | Notes |
|---|---|---|
| 1 | Bottom plate component loading | Position and place using a fixture board positioning device |
| 2 | Compressor assembly and fixation | Slightly shake the compressor after assembly to ensure that the feet are fully inserted into the vibration-reducing rubber ring |
| 3 | Condenser bending and assembly | N/A |
| 4 | System component assembly | Connect components such as service valves, four-way valves, check valves, and capillary tubes |
| 5 | Nitrogen purging | Use low-pressure nitrogen to displace air inside the system before welding |
| 6 | Manual brazing of system components | Weld the joints of the system components |
| 7 | Motor bracket assembly and fixation | Check the motor model and appearance, ensure the bracket is not deformed |
| 8 | Connection of quick connectors | Ensure reliable connection to prevent high-pressure blow-off injuries |
| 9 | System pipe shaping | Ensure pipes are straight and parallel, with a spacing of more than 10mm between moving pipes |
| 10 | Vacuum box helium leak detection | Detect the amount of helium leaked into the vacuum box |
| 11 | System vacuum extraction | Use dual paths to extract vacuum simultaneously to ensure all parts of the system are evacuated |
| 12 | Axial fan assembly and fixation | Ensure good dynamic balance performance |
| 13 | Refrigerant charging | Set the charging amount according to design requirements and complete the charging process automatically |
| 14 | Process pipe sealing | Clamp with a pneumatic press tool to prevent refrigerant leakage |
| 15 | Halogen leak detection | Detect leak rate to ensure it is below the set value |
| 16 | Electrical control assembly and wiring | Organize the wiring to meet safety standards |
| 17 | Four safety performance checks | Ensure the air conditioner has good electrical safety performance |
| 18 | Final inspection of the complete machine | Test cooling and heating operation |
| 19 | Rear-end assembly | Includes assembly and fixation of appearance structural components, as well as the attachment of labels and nameplates |
| 20 | Packaging | N/A |
Testing Process Table
| Process | Content | Standard |
|---|---|---|
| 1 | Appearance inspection | Check for scratches, deformations, or other defects on the air conditioner |
| 2 | Performance testing | Ensure cooling and heating performance meets design requirements |
| 3 | Electrical safety testing | Check for safe electrical connections and absence of electrical leakage |
| 4 | Noise testing | Ensure noise levels are within the specified range |
| 5 | Vacuum degree testing | Ensure system vacuum reaches the set value |
| 6 | Helium leak detection | Ensure the leak rate of the complete machine system is below the set value |
| 7 | Halogen leak detection | Detect refrigerant leakage, ensuring the leak rate is below the set value |
| 8 | Low-voltage start-up testing | Test with 85% of the rated voltage; the compressor should start normally to be qualified |
| 9 | Cooling and heating operation testing | Check the coarse pipe pressure and the temperature difference between the inlet and outlet to ensure they are within the set range |
| 10 | Subjective inspection of complete machine operation | Check for stable operation and absence of abnormal noise |
The above is a detailed description of a small-scale domestic air conditioner assembly production line, along with the assembly and testing process tables.