Fan durability online test under all working conditions

High and low voltage cycle operation, monitoring noise, current, and speed fluctuations;

Flexible compatibility with multiple specifications of fans

Cooling fans of different sizes are assembled on the same line, and the replacement program can be switched with one click;

Pipeline synchronous leak detection unit

The air tightness of the condenser pipeline is directly tested after assembly to prevent refrigerant leakage;

Servo tightening torque graded control

Different torque thresholds are distinguished for brackets and pipe joints to accurately control the assembly process;

Multi-device collaborative communication

Robots, tightening spindles, leak detectors, vision equipment Profinet high-speed synchronization;

Automatic fault diversion and sorting

Abnormal fan current and defective products with pipeline leakage are automatically diverted to the repair area.

Parameter items

Technical indicators

Adapted products

Passenger car/commercial vehicle front-end condenser + electronic fan integrated module

standard beat

210s/piece

control system

Siemens S7-1500 PLC, 15-inch industrial HMI

Tightening torque range

1~30N・m, accuracy ±2%

Fan test voltage

12V/24V dual specifications compatible, current accuracy ±0.05A

Airtight leak detection accuracy

≤4×10⁻⁴ mbar·L/s

Traceability carrier

RFID metal tray, resistant to oil stains and high temperatures

Production line area

50m×4m

Communication speed

Profinet 100Mbps, multi-station synchronization without delay

Integrated assembly of cooling module

The robot automatically grabs the condenser, fan bracket, and electronic fan, accurately aligns the servo positioning tooling, tightens the bracket bolts and pipe joints synchronously on multiple axes, and records the assembly torque of each location in real time. Tightening leaks and torque deviations will automatically alarm and shut down.

Visual appearance defect detection

Industrial vision detects condenser fin deformation, pipe bumps, fan blade damage, and missing wire harness buckles, automatically marks defect types, and simultaneously stores image files for quality review.

Electronic fan durability performance test

Simulate the high and low voltage power supply fluctuations of the vehicle, run the fan in full-load cycles, collect speed, operating current, and operating noise, and identify potential faults such as bearing wear, coil short circuit, poor dynamic balance, etc., to avoid abnormal noise and burnout of the fan while the vehicle is running.

Condenser pipeline air tightness leak detection

Perform pressurized dry vacuum leak detection on refrigerant pipelines, detect micro-leakage in pipeline joints and condenser welds, and eliminate the problems of vehicle air conditioning refrigerant leakage and refrigeration failure from the source.

Full-link digital traceability management

Each cooling module is bound to the pallet RFID, and the assembly torque, fan electrical performance, and leakage detection data are simultaneously uploaded to the MES system to meet the full life cycle traceability audit requirements of the OEM parts.

Commercial value: The factory defective rate of front-end cooling modules has been reduced by 90%. A single production line has replaced 7 assembly inspection personnel, saving more than 700,000 yuan in labor and after-sales claim costs every year.