1.Project background

Juneng Technology is an energy storage system integration company. With the explosive growth of large storage and industrial and commercial energy storage orders, the production capacity gap of liquid cooling units continues to expand. The original semi-automated production line has scattered processes and relies on manual inspection links, which cannot meet the high safety, high traceability, and high-tempo production requirements of the energy storage industry. There is an urgent need to build a new high-standard fully automatic line to support the rapid expansion of the business.

2. Core pain points

1. The production expansion cycle is tight, the order delivery pressure is high, and the traditional production line construction cycle is long, which cannot match the pace of business growth;

2. Energy storage safety requirements are strict. The sealing and electrical performance of the liquid cooling system are directly related to the safety of the entire machine. The risk of missed detection in manual inspection is high;

3. The testing process is scattered, with air-tightness, safety regulations, rain exposure, and aging at multiple stations. The efficiency is low, the data is fragmented, and quality traceability is difficult;

4. The power model of the unit is iterated quickly, and the traditional rigid production line is not flexible enough, making it difficult to adapt to the co-line production of multi-specification products.

3. Overall solution

Guangke Industrial relies on its technological accumulation in the field of thermal management to create an integrated liquid-cooled unit line solution for customers with "intelligent assembly + full-dimensional inspection + aging verification + digital management". It adopts a circular lean layout and integrates pallet RFID for full-process traceability, covering the entire process from core component loading to finished product aging and final testing. It strictly benchmarks energy storage safety-level production standards while taking into account the flexible production needs of multi-power models to ensure customers' rapid production and stable mass production.

4. Solution core configuration

1. Circular lean production line layout: A circular production line with pallet circulation is used. The work stations are compactly arranged, shortening the material turnover path, adapting to large-volume continuous production, and reserving stations for later expansion of production;

2. Full-process intelligent assembly: The core workstation adopts robot + intelligent tightening system, precise assembly with fixed torque and fixed angle, real-time uploading of tightening data, and controllable assembly accuracy throughout the entire process;

3. Multi-dimensional safety testing system: integrated air tightness testing, safety testing, rain testing, software system function testing, full-dimensional verification of unit sealing, electrical, and operating performance, and automatic diversion of unqualified products;

4. Finished product aging operation verification: Set up an exclusive aging test area to simulate actual working conditions and carry out load operation tests to detect early failure risks in advance and ensure the long-term operation stability of the factory units;

5. RFID full-process traceability: pallets are bound to product information, assembly, testing, and aging data are retained throughout the entire process, and the entire link of a single product is traceable, meeting the safety traceability requirements of the energy storage industry;

6. Production visual management: Equipped with electronic signage in the workshop to display output, tempo, yield, and abnormal information in real time, making the production status transparent and improving on-site management efficiency.

5. Project implementation results

1. Rapid delivery and production: The entire line only takes 3 months from plan confirmation to mass production, effectively supporting the delivery of customer orders and easing the production capacity gap;

2. Quality and safety standards are met: the factory yield of finished products is stable at above 99.5%, there are zero batch hidden dangers in sealing and electrical performance, and it has successfully passed the energy storage industry safety certification;

3. Improvement of production efficiency: the automation rate of the entire line reaches 85%, the single-shift production capacity increases by 45%, and the overall equipment efficiency (OEE) stabilizes at more than 90%;

4. Improved traceability system: the whole process data is 100% traceable, meeting the safety traceability and customer quality audit requirements of the energy storage industry;

5. Enhanced flexible adaptation: Supports co-line production of multi-power liquid cooling units, shortens product changeover time by 60%, and adapts to rapid product iteration requirements.

6. Customer value and evaluation

This project is the customer's first fully-automated production line for liquid-cooling units that was fully independently planned. After being put into production, it has been operating stably, with both production capacity and quality exceeding expectations. It has strongly supported the large-scale expansion of the energy storage business of Juneng Technology's customers. The production line's safety management and control capabilities and traceability system have also become the benchmark in the customer's supply chain system, and have been highly recognized by terminal power station customers.