The assembly process and production line of manual, electric, and fuel forklifts involve multiple stages. It starts with precise parts processing, followed by pre-assembly and final assembly. Inspection and finishing ensure product quality. The production line features automated conveying systems, modular assembly lines, and advanced equipment for welding and painting. Information management systems like MES optimize production efficiency. This comprehensive approach guarantees high-quality forklifts with improved efficiency and reliability, meeting diverse market demands.

Assembly Process and Production Line of Manual, Electric, and Fuel Forklifts

I. Assembly Process

(1) Parts Processing and Preparation

1. Chassis Manufacturing

• Material Selection: High-strength steel is used to ensure the structural strength and durability of the chassis.
• Processing Technology: The main structure of the chassis is manufactured through laser cutting, numerical control bending, welding, and other processes.
• Quality Control: Non-destructive testing (such as X-ray inspection) is conducted on welding points to ensure welding quality.

1. Hydraulic System Components Processing

• Hydraulic Pump: Precision casting and machining technologies are used to ensure the efficient operation of the hydraulic pump.
• Cylinder: High-precision machining and surface treatment are applied to improve the sealing and durability of the cylinder.
• Valves and Tubing: High-quality sealing materials and connection technologies are used to ensure the reliability of the hydraulic system.

1. Power System Components Processing

• Internal Combustion Engine: The engine undergoes strict quality inspection to ensure its performance and reliability.
• Electric Motor: High-efficiency motors are used to ensure the power output of electric forklifts.
• Battery: High-capacity, long-life batteries are selected to ensure the endurance of electric forklifts.

1. Other Components Processing

• Forks: Manufactured from high-strength steel to ensure their load-bearing capacity and durability.
• Tires: Wear-resistant and anti-slip tires are chosen to enhance the forklift’s driving performance.
• Cab: Ergonomic design is applied to ensure the comfort and operational convenience for the driver.

(2) Pre-assembly and Sub-assembly

1. Chassis Pre-assembly

• Fuel Tank Installation: The fuel tank is securely mounted on the chassis to ensure stability and safety.
• Rear Post of the Overhead Guard Installation: The rear post of the overhead guard is installed to enhance the safety of the forklift.
• Tilt Cylinder Installation: The tilt cylinder is mounted on the chassis to ensure smooth operation.

1. Power System Pre-assembly

• Internal Combustion Engine Installation: The engine is mounted on the chassis, with the radiator, exhaust pipe, and other components connected.
• Electric Motor Installation: The electric motor is mounted on the chassis, with the battery and control unit connected.
• Battery Installation: The battery is securely mounted on the chassis to ensure stability and safety.

1. Hydraulic System Pre-assembly

• Hydraulic Pump Installation: The hydraulic pump is mounted on the chassis, with the cylinder and tubing connected.
• Cylinder Installation: The cylinder is mounted on the chassis to ensure smooth operation.
• Tubing Connection: Hydraulic tubing is connected to ensure the sealing and reliability of the hydraulic system.

(3) Final Assembly

1. Body Final Assembly

• Chassis and Power System Integration: The pre-assembled chassis and power system are integrated to ensure a secure connection.
• Hydraulic System Installation: The hydraulic system is mounted on the chassis, with the hydraulic pump, cylinder, and tubing connected.
• Electrical System Wiring: The battery, control unit, wiring, and other electrical system components are installed to ensure correct connections.

1. External Components Assembly

• Cab Installation: The cab is mounted on the chassis, with the seat, steering wheel, dashboard, and other components connected.
• Forks Installation: The forks are mounted on the forklift to ensure a secure fit.
• Tires Installation: The tires are mounted on the forklift to ensure correct installation.
• Lighting Installation: Front headlights, taillights, turn signals, and other lighting components are installed to ensure proper illumination and warning functions.

(4) Inspection and Commissioning

1. Static Inspection

• Appearance Check: The overall appearance quality of the forklift is inspected, including paintwork and the installation of components.
• Component Check: The installation of each component is checked for stability and correct connections.

1. Dynamic Commissioning

• No-load Running Test: The forklift is tested in a no-load running state to check its driving speed, braking performance, and other parameters.
• Loading and Unloading Test: The forklift is tested in a loading and unloading state to check its mast tilt speed, lifting speed, and other performance parameters.
• Performance Testing: The hydraulic system, electrical system, and other functions of the forklift are tested to ensure proper operation.

(5) Finishing and Storage

1. Finishing Treatment

• Cleaning: The forklift is cleaned to remove dust and debris from the surface.
• Touch-up Painting: Scratches and damages on the surface are touched up with paint to improve the appearance quality of the product.

1. Storage and Dispatch

• Storage: The finished products are stored in the warehouse, categorized and stored properly.
• Dispatch: The products are packaged and dispatched according to order requirements.

II. Production Line Layout

(1) Conveying System

1. Underground Chain Conveyor Line

• Function: Used for conveying forklift components to ensure the orderly flow of parts.
• Features: Installed below ground level, saving space and improving production efficiency.

1. Push Chain Conveyor Line

• Function: Auxiliary conveyor line, working in conjunction with support fixtures and KBK cranes.
• Features: Flexible configuration to meet the conveying needs of different components.

(2) Assembly Line

1. Chassis Pre-assembly Line

• Function: Completes the pre-assembly of the chassis and related components.
• Features: Modular design for quick assembly and adjustment.

1. Final Assembly Line

• Function: Completes the final assembly of the forklift.
• Features: Equipped with various assembly tools and equipment to ensure assembly quality and efficiency.

1. Inspection Line

• Function: Conducts inspection and commissioning of the forklift.
• Features: Equipped with advanced inspection equipment to ensure product quality.

(3) Automated Equipment

1. Automated Welding Robots

• Function: Improves welding quality and efficiency.
• Features: High-precision welding to reduce human error.

1. Painting Line

• Function: Surface treatment and painting of the forklift.
• Features: Automated painting to improve painting quality and efficiency.

(4) Information Management

1. Manufacturing Execution System (MES)

• Function: Real-time monitoring of production progress, optimizing resource allocation, and improving production efficiency.
• Features: Integration of various production data to achieve intelligent management.

III. Process Features Table

Summary

The assembly process and production line of manual, electric, and fuel forklifts are complex and meticulous system projects, covering multiple stages from parts processing to final product inspection. Through precise processing technologies, efficient assembly processes, and advanced inspection equipment, the quality and performance of the products are ensured. Meanwhile, the application of information management and automated equipment further enhances production efficiency and management levels.