Household Heat Pump Assembly Testing and Packaging Production Line
The Household Heat Pump Assembly, Testing, and Packaging Production Line is a highly automated and intelligent system designed for manufacturing household heat pumps. It integrates various processes, including component assembly, performance testing, and final packaging. The line features advanced equipment such as high-frequency welders, leak detectors, and vacuum drawing machines to ensure product quality and efficiency. With high-precision processing and testing capabilities, it guarantees the reliability and performance of heat pumps. The system also includes logistics and warehousing solutions for efficient material handling and product distribution.
Detailed Description of the Household Heat Pump Assembly, Testing, and Packaging Production Line
1. Overview of the Production Line
The Household Heat Pump Assembly, Testing, and Packaging Production Line is a highly integrated, automated, and intelligent production system specifically designed for manufacturing household heat pumps. The production line covers the entire process from component assembly to performance testing and final packaging, ensuring product quality and production efficiency. Equipped with advanced automated equipment and digital management systems, it achieves efficient and precise production processes.
2. Main Processes of the Production Line
(1) Raw Material Preparation
- Description: Preparation of raw materials and components required for heat pump production, including compressors, evaporators, condensers, expansion valves, refrigerants, and electrical components. These materials undergo strict quality inspection to ensure they meet production standards.
- Equipment: Raw material warehouse, shelving, forklifts, AGV (Automated Guided Vehicles) for logistics.
- Parameters: Warehouse area, shelving capacity, forklift load capacity, AGV operating speed, etc.
(2) Component Manufacturing
- Description: Processing and manufacturing of core components for heat pumps, such as compressor assembly, evaporator and condenser welding, and precision machining of expansion valves. This stage requires high-precision processing equipment and strict quality control.
- Equipment: CNC machining centers, welding robots, high-frequency welding machines, laser cutting machines, etc.
- Parameters: Machining accuracy, welding quality, equipment power, machining speed, etc.
(3) Component Assembly
- Description: Assembly of processed components to form a complete heat pump system. This includes connecting evaporators and condensers to compressors, installing pipes, valves, and electrical components. The assembly process must ensure accurate connections and sealing.
- Equipment: Assembly workstations, automatic torque wrenches, AGV logistics vehicles, KBK hoisting equipment, etc.
- Parameters: Assembly accuracy, torque, equipment load capacity, assembly speed, etc.
(4) Refrigerant Injection
- Description: After the heat pump system is assembled, refrigerant injection is performed. Accurate and efficient refrigerant injection is crucial, and leakage must be avoided.
- Equipment: Refrigerant injection machines, refrigerant recovery machines, vacuum pumps, etc.
- Parameters: Refrigerant injection volume, injection accuracy, equipment power, injection speed, etc.
(5) System Leak Testing
- Description: Using high-pressure nitrogen to test the heat pump system for leaks, checking the sealing of welded joints and connections. This is an important step to ensure product quality.
- Equipment: Leak testing equipment, high-pressure nitrogen cylinders, halogen detectors, etc.
- Parameters: Testing pressure, detection accuracy, equipment power, testing speed, etc.
(6) System Vacuum Drawing
- Description: Vacuum drawing of the heat pump system to remove air, moisture, and residual refrigerant, ensuring system vacuum and improving heat pump efficiency and lifespan.
- Equipment: Vacuum pumps, vacuum gauges, vacuum drawing pipelines, etc.
- Parameters: Vacuum level, vacuum drawing time, equipment power, etc.
(7) Performance Testing
- Description: Testing various performance aspects of the heat pump, including cooling/heating capacity, water flow rate, electrical parameters, inlet and outlet water pressure difference, temperature difference, and system pressure. The COP value (Coefficient of Performance) is calculated through testing, and safety tests are conducted to ensure compliance with safety standards.
- Equipment: Performance testing stations, water flow meters, electrical parameter testers, safety test instruments, etc.
- Parameters: Testing range, testing accuracy, equipment power, testing time, etc.
(8) Quality Inspection
- Description: Final quality inspection of the heat pump products after all tests are completed. Inspection includes visual checks, performance indicator verification, and safety performance testing to ensure products meet quality standards.
- Equipment: Inspection workstations, testing tools, recording equipment, etc.
- Parameters: Inspection standards, inspection time, equipment accuracy, etc.
(9) Finished Product Packaging
- Description: Packaging of qualified heat pump products, including moisture-proof treatment, shock-proof packaging, and label application. Packaged products are transported to the warehouse or shipped directly.
- Equipment: Packaging machines, packaging materials, logistics equipment, etc.
- Parameters: Packaging dimensions, packaging weight, equipment power, etc.
(10) Logistics and Warehousing
- Description: Transporting packaged finished heat pumps to the warehouse for storage or direct shipping to customers. The logistics process requires an efficient warehouse management system and logistics equipment to ensure timely and accurate delivery.
- Equipment: Forklifts, shelving, logistics conveyors, AGVs, etc.
- Parameters: Warehouse area, shelving capacity, logistics speed, equipment load capacity, etc.
3. Production Line Parameter Table
| Equipment Name | Model | Quantity | Purpose | Main Parameters |
|---|---|---|---|---|
| Conveyor Line | Customized | 1 | Material Conveying | Conveying Speed: 0.5-2.0m/min, Conveying Load: 500kg, Conveying Length: 50m |
| AGV Logistics Vehicle | Customized | 2 | Logistics Transport | Load Capacity: 1000kg, Operating Speed: 1.5m/s, Navigation Method: Laser Navigation |
| KBK Hoisting Equipment | Customized | 2 | Material Hoisting | Lifting Capacity: 1000kg, Working Radius: 5m, Lifting Speed: 0.3m/s |
| Antifreeze Injector | RB75EA | 1 | Antifreeze Injection | Injection Speed: 5L/min, Injection Accuracy: ±1%, Equipment Power: 1.5kW |
| High-Frequency Welder | TD-15MFC | 2 | Welding Evaporators/Condensers | Welding Power: 15kW, Welding Speed: 3m/min, Welding Accuracy: ±0.1mm |
| Leak Testing Equipment | QYH-201 | 1 | System Leak Testing | Testing Pressure: 2MPa, Detection Accuracy: ±0.01MPa, Equipment Power: 0.5kW |
| Vacuum Drawing Equipment | Air | 1 | System Vacuum Drawing | Vacuum Level: -0.1MPa, Vacuum Drawing Time: 10min, Equipment Power: 1.0kW |
| Refrigerant Injector | EXRC-202 | 1 | Refrigerant Injection | Injection Speed: 2L/min, Injection Accuracy: ±0.5%, Equipment Power: 2.0kW |
| Refrigerant Recovery Machine | CMEP-OL | 1 | Refrigerant Recovery | Recovery Speed: 1.5L/min, Equipment Power: 1.2kW, Recovery Accuracy: ±0.5% |
| Halogen Detector | HLD6000 | 3 | Refrigerant Leak Detection | Detection Sensitivity: 1ppm, Equipment Power: 0.3kW, Detection Range: 0-100ppm |
| Rain Test Chamber | 0.5m³ | 1 | Rain Test | Rain Intensity: 50L/min, Testing Time: 30min, Equipment Power: 1.5kW |
| Drying Chamber | 2800×2600×3000mm | 3 | Component Drying | Drying Temperature: 40-80℃, Drying Time: 2h, Equipment Power: 5.0kW |
| Safety Test Instrument | AN1651TH | 2 | Safety Performance Test | Testing Voltage: 0-250V, Testing Current: 0-10A, Equipment Accuracy: ±0.1% |
| Test Power Supply | ANFC015T | 1 | Performance Test Power Supply | Output Voltage: 0-220V, Output Current: 0-15A, Equipment Power: 3.0kW |
| Variable Frequency Power Supply | ANFC120T | 3 | Variable Frequency Test Power Supply | Output Frequency: 0-60Hz, Output Power: 120kW, Equipment Accuracy: ±0.5% |
| Packaging Machine | Customized | 1 | Finished Product Packaging | Packaging Dimensions: 1000×800×600mm, Packaging Speed: 10 pieces/h, Equipment Power: 1.0kW |
4. Features and Advantages of the Production Line
- High Degree of Automation: Advanced automated equipment reduces manual operations, improving production efficiency and product quality.
- Intelligent Management: Equipped with digital management systems for real-time monitoring, data analysis, and fault warning of the production process.
- High-Precision Processing and Testing: High-precision processing equipment and testing instruments ensure the accuracy of component manufacturing