Flexible modular work station design

Workstations can be split independently, assembly/testing units can be added or removed as needed, and vehicle model product changes can be completed in 2 hours;

Full-dimensional high-voltage safety inspection

Integrated insulation withstand voltage, leakage current, temperature rise durability, and CAN communication logic tests, covering the strict access standards of OEMs;

Circular rotating lean layout

Product pallets circulate in circulation, reducing material transfer distance and improving rhythm stability;

Full-link digital traceability

RFID pallet + barcode dual traceability, and the assembly parameters and detection data of each PTC are permanently archived;

High comprehensive utilization rate of equipment

OEE stability ≥90%, Profinet 100Mbps high-speed communication, multi-device synchronization and collaboration without delay;

Human and machine safety protection

Fully enclosed safety fence, photoelectric safety grating, emergency stop chain, automatic shutdown alarm when failure occurs

Parameter items

Technical indicators

Adapted products

New energy water cooling PTC, air heating PTC, voltage 300V-800V

Standard production cycle

180s/piece, can be customized and optimized according to customer production capacity

control system

Siemens S7-1500 PLC + industrial touch HMI

Communication protocol

Profinet, CAN2.0, LIN bus, TCP/IP

Traceability

RFID radio frequency pallet traceability + one-dimensional/two-dimensional barcode scanning and collection

Detection accuracy

Insulation withstand voltage ±0.5% FS, temperature rise ±0.1℃, torque ±3%

Production line area

Standard model 45m×4.2m, can be scaled as needed

drive unit

Servo tightening module, six-axis collaborative robot, circular conveyor line

environment adaptation

Workshop temperature 0~40℃, humidity 30%-80%, no condensation

data storage

Local industrial computer storage + cloud MES docking, data storage ≥10 years

Automatic loading and assembly function

The robot automatically grabs the PTC shell, heating core, sealing gasket, and high-voltage wire harness, performs precise servo press-fitting, multi-axis intelligent torque tightening, automatically distinguishes the torque thresholds of bolts of different specifications, and eliminates missing, false, and over-tightening. High-definition industrial camera visual inspection identifies shell scratches, sealing gasket dislocation, damaged wire harness, terminal skew, and other appearance defects. Defective products are automatically diverted and isolated to intercept the outflow of defective products in advance.

Visual appearance defect detection function

High-definition industrial camera visual inspection can identify appearance defects such as casing scratches, gasket dislocation, wire harness damage, terminal skew, etc. Defective products can be automatically diverted and isolated to intercept the outflow of defective products in advance.

High-voltage power-on aging and electronic control testing

Simulate the VCU signal of the vehicle, issue control instructions through the CAN bus, conduct a 40-minute temperature rise and aging test, and monitor heating power, current, and temperature control protection logic in real time to verify the stability of PTC operation under high and low temperature conditions; simultaneously complete safety testing for voltage resistance, insulation, and leakage current to eliminate high-voltage safety hazards.

Air tightness leak detection function

Dry vacuum leak detection is used to detect leaks in the shell seal pipeline. The micro-leak detection accuracy is ≤1×10⁻⁴ mbar·L/s. No water inspection is required to avoid corrosion of residual water vapor inside the product.

Digital production control function

Real-time dashboard displays production capacity, yield, and equipment failures; MES docking enables work order issuance, material batch binding, root cause analysis of defective products, equipment utilization statistics, and supports management to remotely view production line operation data.

Commercial value: The manufacturing cost of a single piece is reduced by 35%, the defective rate of products is reduced to less than 0.3%, the production capacity is increased by 2 times, and the annual batch delivery demand of 100,000 units can be met by the main engine factory. The equipment investment cost of the complete production line can be recovered within 3 years.