1. Overview of the production line
The vehicle-mounted air compressor production line is an intelligent assembly production line specially designed for the vehicle-mounted air compressor (air compressor), the core component of the braking system of new energy vehicles and traditional fuel vehicles. The entire production line adopts a modular design concept and integrates advanced technologies such as mechanical transmission, automated control, and intelligent testing. It can realize the full-process automated operation from parts loading to finished products offline. The annual production capacity can reach 150,000 – 300,000 sets., meeting the large-scale production needs of mainstream main engine factories.
2. Core process layout
The production line adopts a flexible layout of “zigzag” or “straight line”, and the spacing between stations is accurately calculated to ensure smooth logistics and balanced rhythm. The entire line is divided into four functional modules: pre-assembly area, main assembly area, test area and packaging area:
Pre-assembly area: Complete the pre-assembly of core components such as motor stator and rotor components, crankshaft connecting rod mechanisms, cylinder block and head, and configure an automatic screw locking machine and a real-time torque monitoring system to ensure that key thread connections meet process standards;
Main installation area: Integrate key processes such as automatic assembly of piston rings, precision press fitting of valve assemblies, and automatic oiling and press fitting of oil seals. A six-axis robot is used to cooperate with the servo press fitting system, and the press fitting accuracy is controlled within ±0.02mm;
Test area: Equipped with a fully automatic performance test bench to carry out airtightness test, displacement test, noise and vibration (NVH) test and durability running-in test for each air compressor, and the test data is uploaded to the MES system in real time;
Packaging area: Automatically complete labeling, scanning code, boxing, and palletizing to achieve traceability throughout the product life cycle.
3. Technical characteristics and advantages
1.
Highly flexible design: Through the Rapid Mold Change System (SMED), the switching production of different types of air compressors can be completed in 30 minutes, and is compatible with multiple product types such as single cylinder, double cylinder, and oil-free/oil-lubricated lubrication;
2.
Intelligent management and control: The entire line is equipped with PLC+ industrial Ethernet control system, integrating visual inspection, RFID traceability, and lighting system (Andon) to achieve real-time monitoring of equipment status and fault warning, and the overall equipment efficiency (OEE) is ≥85%;
3.
Zero-defect quality guarantee: SPC process control points are set up at key workstations, and online detection methods such as pneumatic gauges and laser ranging are used to automatically divert substandard products to the repair area to ensure that the factory pass rate is ≥99.5%;
4.
Humanized engineering: The workstation is highly ergonomic and equipped with anti-static workbench, LED lighting and dust removal system to improve the working environment and reduce the labor intensity of workers.
4. Equipment configuration highlights
The conveying system adopts a double-speed chain + tooling board circulation method, and the beat time is adjustable (60-120 seconds/set);
The press fitting equipment uses servo electric cylinders, and the force-displacement curve during press fitting is monitored in real time;
The tightening system adopts intelligent electric batch to support multi-axis synchronous tightening and angle control;
The entire line of air sources, power supplies, and networks adopt standardized interfaces to facilitate later expansion and upgrading.
5. Applicable customer groups
This production line is suitable for automobile brake system parts manufacturers, new energy vehicle supporting enterprises, and professional air compressor manufacturers. It can produce various vehicle-mounted air compressor products with a displacement of 50-500L/min and a rated power of 200W-5kW.
