Air conditioning assembly line

This production line is designed for the large-scale production of outdoor and indoor units of household and commercial air conditioners, using modular layout and intelligent logistics system to realize the whole process of automated operation from sheet metal pre-assembly to finished product inspection. The cycle speed of the production line is adjustable (45-120 seconds/set), compatible with 1-5 horsepower multi-specification product mixed line production, and the annual production capacity can reach 30-500,000 sets.
Core technical features
1. Flexible pallet conveying system The production line adopts the mixture flow mode of accumulation roller and AGV trolley. As shown in the figure, the main body of each air conditioner external unit is placed on a standardized wooden tray, which has a built-in RFID chip to record the product model, work order batch and process parameters in real time. The conveyor line adopts frequency conversion speed regulation, supports buffer accumulation between stations, and effectively balances the cycle time difference of each process.
2. Modular process layout

Pre-installed section: complete the installation of compressor shock absorber pads, pipeline welding, and pre-wiring of electrical appliance boxes. It is equipped with a six-axis robot for automatic brazing of copper pipes, and nitrogen shielding welding ensures that there is no oxide scale, and the leakage rate is controlled below 0.01%

Final assembly section: including compressor hoisting (using assisted manipulator, load 80-150kg), condenser/evaporator insertion, fan motor stator assembly. The key stations are equipped with torque management systems, and bolt tightening data is uploaded to MES in real time

Detection section: helium mass spectrometry leak detection (sensitivity 1×10⁻⁹ Pa·m³/s), vacuum pump pumping freon (charging accuracy ±5g), safety test (withstand voltage 1800V/5mA), operation performance test (rated cooling/heating condition simulation)
3. Intelligent quality traceability Each station is equipped with an industrial flat plate and a barcode scanner, and the key components (compressor, motor, controller) are bound with a unique serial number. If there is an abnormality, the system can lock the range of the same batch of materials within 15 seconds to achieve accurate traceability.
Process in-depth analysis
Copper pipe processing and connection technology The core of energy efficiency in air conditioning and refrigeration systems lies in the design of pipelines. The production line is equipped with a CNC pipe bender, which uses CNC to control the position of the mandrel, and the bending radius can be as low as 1.5D (pipe diameter), and the ovality is controlled within 8%. After the pipe end is formed, the burrs and grease are removed by an automatic cleaning line to ensure that the cleanliness of the system meets the requirements of R32/R410A refrigerant.
Vacuum and refrigerant charging process It adopts a two-stage rotary vane vacuum pump unit, with an ultimate vacuum degree of ≤ 5Pa and a pressure holding leak detection time of ≥ 15 minutes. The refrigerant charging adopts the closed-loop control of the mass flow meter, which automatically compensates the density value according to the ambient temperature to avoid energy efficiency degradation caused by overcharging or undercharging.
Automatic testing of electronic control system Through the CAN bus simulation of host computer communication, the full function test of the frequency conversion driver board is carried out: including PFC circuit efficiency verification (target ≥ 98%), IPM module temperature cycling, and fan speed regulation curve calibration. The test data automatically generates a QR code label that is attached to the product nameplate.
Applicable scenarios
It is suitable for mass manufacturing of split air conditioners, multi-line machines, light commercial cabinets and other products, and supports rapid model change (tooling switching can be completed within 30 minutes).