Pressure fan assembly line

1. Overview of the production line

As the core equipment for industrial gas transportation, medium pressure fans are widely used in environmental protection, printing, textiles, aquaculture, pneumatic transportation and other fields. In order to meet the market demand for high-efficiency, high-quality, and large-volume production of fan products, we adopt a plate-chain assembly line (as the core carrier for the assembly of medium-pressure fan units) to realize the automated flow and precise assembly of the entire process from parts to finished products.

2. Core characteristics of board chain production line

1. Plate and chain conveying system
Steel chain plates are used to drag the workpiece for planar conveying movement. The chain plate pitch is usually 50.8mm or 100 mm. It has the following advantages:
– Strong carrying capacity: A single station can carry the weight of the medium pressure fan (50-360kg), meeting the assembly needs of aluminum pump bodies, motors and other heavy parts.
– Smooth operation: The chain plate and guide rail are accurately matched, and the conveying speed is adjustable from 0.4 to 15m/min, supporting two modes of continuous operation and rhythmic operation.
– Wear resistance and durability: The surface of the steel chain plate has been specially treated to adapt to long-term high-frequency working environment in industrial workshops
2. Modular workstation design
The production line adopts a combined assembly mode, and the number of stations is freely set according to the assembly process of the medium pressure fan. Configuration items:
1. Fluorescent lighting: Ensure sufficient light for precision assembly operations.
2. Process drawing board: display current workstation assembly drawings and work instructions in real time
3. Tool box +220V power outlet provides convenient access to power for power tools.
4. Air pipe quick change interface: support the use of pneumatic wrenches, pneumatic lifting and other tools
5. Part magazines: Preset standard parts and accessories according to the workstation to achieve lean material management

3. Assembly process of medium pressure fan plate chain
The first stage: pump body pre-assembly stationHousing positioning: Place the aluminum alloy die-cast pump body (scroll shell) on the plate chain fixture to ensure uniform positioning benchmark

Impeller pre-assembly: Install the aluminum alloy impeller corrected by dynamic balance into the pump body, and adjust the gap between the impeller and the pump casing to the design value (usually 0.3-0.5mm)
Bearing housing installation: Press fit high-precision bearings to ensure coaxiality of the rotor system
Phase 2: Motor assembly station
Motor stator installation: butt the three-phase asynchronous motor (power range 0.25-25kW) with the pump body flange
Rotor threading: Thread the rotor assembly with impeller into the motor stator to adjust the air gap uniformity
– End cap locking: Tighten the connecting bolts in diagonal order in several times, and the final tightening torque is implemented in accordance with the process specifications

Phase 3: Gas circuit system assembly station
– Air inlet and outlet flange installation: Install standard flange interfaces to ensure the flatness of the sealing surface
– Silencer/filter assembly: Install intake filter according to customer configuration requirements
– Pipeline seal testing: Use air pressure testing method to verify the tightness of each interface

Phase 4: Electrical and Test Stations
– Installation of wiring strip: Complete U/V/W three-phase wiring according to the motor wiring diagram
– Insulation resistance test: Ensure that the insulation resistance of the motor is ≥2MΩ (complies with GB4706.1 standard)
– Performance test of the whole machine:
– Air volume test: Use a wind tunnel test bench to verify the rated air volume (deviation ≤±5%)
– Pressure test: Check whether the maximum differential pressure (vacuum/pressure) meets the standard
– Noise test: Operating noise must be ≤75dB(A)(measured 1 meter away from the fan)
– Vibration test: vibration speed at the bearing ≤7.1mm/s

Stage 5: Appearance treatment and packaging station
– Surface cleaning: Remove residual aluminum chips and oil stains during assembly
– Nameplate attachment: laser marking product model, serial number, technical parameters
– Anti-rust treatment: spray anti-rust oil on exposed processed surfaces
– Finished product packaging: bagging for protection and put into the box, with product certificate and instructions for use attached

4. Technical parameters of the production line

1. Length of wire body: customized according to process requirements (typical configuration is 30-80 meters)
2. Line width: 800-1500mm (adjusted according to fan specifications)
3. Working surface height:750mm±25mm (ergonomic)
4. Transport medium: steel plate chain (pitch 50.8/100mm)
5. Running speed: 0.5-15m/min (frequency conversion speed regulation)
6. Power configuration: electromagnetic speed regulation/variable frequency speed regulation control
7. Station spacing| Set according to the operating rhythm of single station (usually 1.2-2.0 meters/station)
8. Applicable products| Medium pressure fan (power 0.25-25kW series)

5. Quality control and intelligent upgrade

1. Full process quality traceability: Each workstation is equipped with a process billboard, which displays assembly points with pictures and texts; torque check points are set for key processes (such as bearing press fitting and bolt tightening), and data is uploaded to the MES system in real time to realize the full life cycle of a single product.
2. Human-machine collaborative automation: For highly repetitive processes (such as gluing and screw locking), collaborative robots can be introduced to achieve human-machine collaborative work, improve assembly consistency and reduce labor intensity.
3. Digital management: Through the integrated RFID station identification system of the board chain line, the process parameters of the corresponding products are automatically retrieved to avoid wrong and missed installation during mixed-line production, and to support mixed-flow assembly of multiple models of medium pressure fans.

6. Conclusion

The medium pressure fan plate chain assembly production line uses steel chain plates as the conveying carrier and combines modular station design and lean process flow to achieve efficient production from pump body pre-assembly, motor assembly, gas path integration to performance testing. This production line not only greatly improves the assembly efficiency and product quality stability of intermediate-pressure fans, but also lays a solid foundation for enterprises to achieve large-scale, standardized and intelligent manufacturing.