1.Project background

Sanhua Intelligent Control is a global leader in thermal management components. As the trend of thermal management integration in new energy vehicles accelerates, the complexity of water integrated module products continues to increase, integrating valve groups, pipelines, heat exchangers, sensors and other types of components. The original semi-automated production lines are no longer able to meet the requirements for high-precision assembly and high-reliability sealing, and there is an urgent need to upgrade dedicated automated assembly lines.

2. Core pain points

1. The product is highly integrated, the assembly process is complex, the precision of manual assembly is unstable, and there are many hidden dangers in sealing performance;

2. There are few sealing detection stations, the risk of missed detection is high, and after-sales leakage problems affect brand reputation;

3. Collaborative assembly of multiple components results in cumbersome process flow, low production efficiency, and difficulty in increasing production capacity;

4. Assembly parameters and testing data are scattered, and the quality traceability chain is incomplete, making it impossible to meet the traceability requirements of high-end customers.

3. Overall solution

In view of the complex structure and strict sealing requirements of water-integrated module products, Guangke Industrial customized a linear automated assembly line, adopting the process idea of "segmented assembly + segmented inspection". The core process is fully automated, multi-station air tightness testing is checked at all levels, and a full-process data traceability system is provided to ensure product assembly accuracy and sealing reliability.

4. Solution core configuration

1. Precision loading and positioning system: visually position and load components such as shells, valve groups, heat exchangers, sensors, etc., verify material specifications and directions, and ensure assembly accuracy from the source;

2. Robotic precision assembly unit: The core components are precision assembled by robots, and all key threaded connections are tightened using intelligent fixed torque. Tightening data is uploaded in real time, and the assembly force is accurately and controllable;

3. Multi-stage sealing detection system: Air tightness detection stations are set up in stages, covering all flow channels and interfaces, high-precision micro-leakage detection, and layer-by-layer checks to eliminate hidden dangers of leakage;

4. Water flow performance test unit: simulate water flow test under actual operating conditions, verify flow rate, pressure drop, valve group switching function, and comprehensively assess product performance;

5. Full-process traceability system: a traceability code is bound to a single product, assembly parameters and inspection data are retained throughout the process, and quality problems can be accurately located to specific processes and material batches;

6. Modular flexible design: Supports co-line production of water-integrated modules of different structures, facilitates model changes and adjustments, and adapts to product iterative upgrades.

5. Project implementation results

1. Production efficiency increased by 40%: With full-process automation, single-shift production capacity increased by 40%, process turnaround time was significantly shortened, and production efficiency was significantly improved;

2. Zero-batch hidden dangers in sealing quality: multi-stage air-tightness detection system, sealing detection accuracy is 100%, zero-batch leakage of factory products, and after-sales failure rate is greatly reduced;

3. Assembly accuracy is stable and controllable: The core assembly process is automated, product consistency is significantly improved, and the assembly accuracy compliance rate is 100%;

4. The traceability system is comprehensively improved: the whole link data is traceable, meeting the supply chain traceability requirements of high-end vehicle customers, and successfully passing customer quality audits.

6. Customer value and evaluation

This production line successfully solves the problems of assembly accuracy and sealing reliability of highly integrated water modules, assists the rapid mass production and delivery of Sanhua intelligent water control integrated module products, and stably supports many leading new energy car companies, becoming the core production capacity support for customers' integrated thermal management products.