1. Overview of the production line
This production line is specially designed for 2- 10kW portable gasoline generator sets and 5- 20kW diesel generator sets. It adopts modular layout and flexible manufacturing concept, and is compatible with mixed-line production of multiple types of models such as single cylinder/double cylinder, air-cooled/water-cooled. The beat of the entire line is adjustable (3-8 minutes/set), and the annual production capacity reaches 150,000 – 300,000 units, meeting the needs of large-scale and customized production of small and medium-power generating units.
2. Core technology architecture
1. The intelligent conveying system production line adopts a composite conveying mode of double-speed chain + stacking and releasing roller table, and a pneumatic blocking and positioning mechanism is configured between the workstations to achieve accurate parking of trays (positioning accuracy ±0.5mm). The power unit is equipped with a variable-frequency speed-regulating motor that supports stepless speed change of 0.5-5m/min to adapt to the working rhythm of workstations with different complexity. The tray has a built-in RFID chip that binds model formula, process parameters and quality traceability data in real time.
2. Modular assembly stations
Powertrain pre-assembly area: equipped with power-assisted manipulator and spring balance crane to achieve accurate docking of engine and motor stator and reduce manual handling intensity
Fuel system assembly line: integrated tightness detection station, differential pressure type air tightness tester is used for online leakage detection of fuel tank and oil circuit (resolution 0.1kPa)
Electrical system test island: automatically complete voltage regulator characteristic curve test, insulation withstand voltage test (AC1500V/1min) and no-load voltage stability verification
Hot test running-in area: Independent enclosed cabin design, equipped with exhaust gas extraction and noise isolation system, achieving factory hot running-in under 75% load conditions
3. A suspended sliding contact line power supply system is deployed above the intelligent logistics and error prevention line to provide stable power for power tools and testing instruments. Key workstations are equipped with photoelectric sensors and torque management systems to monitor the bolt tightening sequence and torque value (±3% accuracy) in real time, and automatically alarm missed tightening or over-tolerance and lock and release.
3. Technological highlights
Flexible replacement ability: Through PLC program switching and quick replacement tool design, replacement of different power models can be completed within 30 minutes, and the replacement loss time is reduced by 60%.
Quality traceability system: From the launch of parts to the launch of finished products, 200+ key quality data points are collected throughout the entire process, supporting the full life cycle traceability of a single engine.
Ergonomic optimization: The height of the workstation is adjustable (750-950mm), materials are delivered regularly by lean material racks and AGVs, and the picking and placing distance is controlled within 30cm, which complies with ISO 11226 ergonomics standards.
IV. Technical indicators
Project parameters:
Line length: 45-65m (expandable)
Number of workstations: 12-18 (modular increase and decrease)
Compatible power range: 2-20kW
Automation rate: 35%(conveying/testing/tightening)
Overall equipment efficiency (OEE): ≥85%
This production line upgrades traditional discrete assembly to digital continuous flow production. While ensuring product quality consistency, it significantly reduces work-in-process inventory and labor dependence. It is the core equipment for generator set manufacturing companies to achieve intelligent manufacturing upgrades.
