1.Project background

Shenling is a leading brand in the domestic industrial and commercial energy storage field. Factory testing of liquid-cooled units relies on manual division of work. The process is cumbersome and inefficient. The test results are greatly affected by human operations, and the data is scattered and difficult to trace. With the rapid growth of shipments, the testing process has become a bottleneck in production capacity and quality control.

2. Core pain points

1. There are many test items, and the air tightness, safety, performance, and aging divisions are manually operated, the circulation is cumbersome, the test efficiency is low, and the overall shipment pace is slowed down;

2. There are errors in manual operation and judgment, the consistency of test results is poor, the risk of missed detection and misjudgment is high, and there are hidden quality risks;

3. Manual recording and archiving of test data is error-prone, difficult to retrieve, makes quality traceability difficult, and cannot meet the audit requirements of end customers;

4. There are many types of units, and the adjustment of test parameters for different power models is cumbersome and the adaptation efficiency is low.

3. Overall solution

Guangke Industrial has built an integrated fully automatic test production line to address the pain points of customer testing. Integrating the four core modules of air tightness test, safety test, operating performance test and aging test, it adopts pallet flow + automatic docking design, unmanned test process, automatic data collection and judgment, and is equipped with a test data management system to achieve standardization, digitization and traceability of the entire test process.

4. Solution core configuration

1. Integrated test layout: air tightness, safety, performance, and aging processes are arranged in sequence, pallets are automatically transferred, and test interfaces are automatically connected to reduce manual intervention;

2. Fully automatic testing process: After the product goes online, various tests are automatically completed, parameters are automatically matched, results are automatically determined, and unqualified products are automatically diverted without manual operation;

3. Multi-dimensional testing capabilities: covering safety tests such as air tightness testing, insulation withstand voltage, performance testing such as flow and pressure drop, and load aging operation testing to comprehensively control factory quality;

4. Intelligent data management: test data is automatically collected and stored, bound to product traceability codes, can be queried, exported, traceable, and test reports are automatically generated;

5. Intelligent adaptation to multiple models: Scan the QR code to automatically identify the product model, match the corresponding test parameters and standards, and support collinear testing of multi-power models;

6. Abnormal warning mechanism: real-time alarms for test abnormalities and automatic analysis of data trends to help identify batch quality risks in advance.

5. Project implementation results

1. Test efficiency increased by 60%: Fully automatic circulation test, the test cycle of a single unit is greatly shortened, and the test production capacity is increased by 60%, effectively supporting shipment growth;

2. Zero misjudgment of test results: standardized automatic testing and determination, the accuracy of test results reaches 100%, completely eliminating the risk of manual misjudgment and missed detection;

3. Comprehensive and improved data traceability: test data is automatically retained, single product test reports are exported with one click, and the end customer quality audit is successfully passed;

4. Significant reduction in labor costs: 80% fewer operators are needed in the testing process, significantly reducing labor costs and personnel operation intensity.

6. Customer value and evaluation

After the test line was put into production, it completely solved the quality control bottleneck of Shenling before shipment, and the testing efficiency and data standardization were greatly improved. It not only ensured the shipment speed, but also strengthened the quality control ability. It became an important part of the customer's quality management system and was unanimously recognized by the customer's operation and maintenance and quality departments.