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No.
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Detailed Requirements
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Criticality (Special Key / Important / General)
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1
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180° Bending Machine (1-out-8):
1. Function: Dedicated equipment for bending long U-shape aluminum tubes for refrigerator direct-insertion fin evaporators. The machine adopts a touch screen as the operation and setting interface, PLC centralized control, and solenoid valves to control cylinder actions, thus realizing simultaneous bending of 8 aluminum tubes. The equipment is suitable for bending Φ8 mm aluminum tubes into long U-shapes.
2. Composition of this station: machine bed and bending wheel assembly.
3. Machine bed: linear design with an aluminum profile flip frame.
4. Bending wheel: manufactured from precision mold steel, driven by a high-power motor combined with a worm-gear reducer to realize bending of 8 aluminum tubes simultaneously.
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Important
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2
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Fin Punching Machine (1-out-6):
1. Function: Dedicated fin punching equipment for refrigerator evaporators. Controlled centrally by an FX2N series PLC, with adjustable punching speed via frequency inverter.
2. Main technical parameters:
1) Applicable raw material: aluminum foil coil, width 286–380 mm, thickness 0.12–0.2 mm;
2) Punching speed: 160–180 strokes/min;
3) Output quantity: 1-out-6 fin mold.
3. Product quality:
1) Fins shall be flat, with overall blanking free from burrs and indentation marks;
2) Flanging height of punched holes shall be consistent; no cracks, step marks or roll-over at the hole edge and flanging root;
3) Qualified rate of punched fins ≥ 99%.
4. Scope of supply: one punching machine (including 1-out-6 fin mold) and one uncoiler and feeder set.
1) Structure of punching machine: composed of frame, drive mechanism and control system, centrally controlled by FX2N series PLC, punching speed adjustable by inverter, and operation steps performed according to touch screen instructions. The machine has both manual and automatic modes (for maintenance, commissioning and die calibration). All motions can be jogged. Aluminum foil feeding is servo-controlled, with servo motor driving feed rollers under PLC control; feeding length is set via the touch screen.
2) In automatic mode, pressing the "Auto Start" button will cause the equipment to run automatically according to the preset program. When the set fin quantity is reached, punching stops automatically, the accumulation rack moves backward–rotates–moves forward, and the next cycle starts.
Electrical control system: uses a programmable controller as the main control element, receiving signals from various sensors and buttons, and controlling contactors and other actuators to complete corresponding actions, with touch screen operation.
3) The uncoiler and feeder are used to pay off the aluminum foil coil. The coil support is designed according to the coil core size provided by Party A, driven by motor with frequency speed regulation.
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Important
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3
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Automatic Fin Stacking and Tube Expanding Machine (according to product):
1. Function: Dedicated equipment for the fin stacking and tube inserting process of refrigerator evaporator fins.
2. Main parameters:
- Applicable raw materials: fins (thickness 0.127–0.2 mm); aluminum tube wall thickness 0.6–1 mm;
- Fin stacking table size: four stations, 5500 × 800 mm (L × W);
- Stacking speed: 10–20 m/min;
- Output quantity: 2 sets/cycle;
- Demolding method: cylinder ejection.
3. The machine consists of frame, working table, automatic fin stacking carriage, pneumatic system and control system, centrally controlled by an FX2N series PLC.
4. The fin stacking mold strip is fixed on a height-adjustable mold base, with the mold in the top position during stacking. Operators place fins into the automatic stacking device, start the stacking carriage, and fins slide under gravity through the guide chute, guided by steel pins through the stacking head into the mold slots one by one. Automatic stacking rate is higher than 90% (missing fins are manually supplemented). After stacking is completed, U-shaped aluminum tubes are inserted into the fin holes. With suitable expanding mandrel wires and a traction carriage, the mandrel is pulled through the aluminum tubes to expand them. The mandrel wires are guided by multiple movable positioning plates. After expansion, the aluminum tubes and fins form a proper interference fit to fix both together, completing the tube expanding process.
5. Press the demolding button, the lifting cylinders drive the mold downward, so that the expanded tube strip is released from the fin mold for product removal.
6. During tube insertion and expanding, the stacking carriage simultaneously switches the feed channel to another mold station for the next stacking cycle.
7. Electrical control system:
- Uses a programmable controller as the main control element, receiving signals from various sensors and buttons, and controlling contactors and other actuators to complete the actions, with touch screen operation.
8. The semi-automatic fin inserting mechanism must be stable and reliable, with no missing insertion, double insertion or fins popping out.
9. Fin stacking molds and fin molds must be precise and wear-resistant, formed by overall assembly to ensure dimensional accuracy and not affect stacking quality.
10. At the manual assisted tube insertion and expanding area, ergonomic requirements must be considered, avoiding excessive operator workload or unnecessary movements.
11. Rubber wheels used for power assistance must have high friction force, be durable and not easily damaged.
12. During movement of the semi-automatic expanding mechanism, each expanding mandrel must be collinear with the aluminum tube, with deviation not exceeding 10 mm to ensure expansion quality.
13. The automatic demolding mechanism must adopt multi-point, multi-force synchronous lifting, with no jamming, uneven lifting, or fin bending and deformation.
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4
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Multi-head Tube Bending Machine (22 heads):
1. This bending machine is a dedicated equipment for bending aluminum tubes of refrigerator pull-expanded fin evaporators. It can continuously bend multiple heads on double-tube or triple-tube assemblies with expanded aluminum tubes of diameter Φ8.45–Φ8.5 mm.
2. Aluminum tube nominal wall thickness: 0.6–1 mm (including inner-tooth tubes).
3. Product processing range:
1) The bending machine designed and manufactured by Party B shall be suitable for tube length range: 240–600 mm (overall envelope size);
2) Bending radius at the tube centerline: R15 mm, with row spacing 25 ± 0.02 mm;
3) The bending machine shall meet product requirements for both 2-tube and 3-tube configurations simultaneously (five grooves shall be provided on the bending wheel).
4. Efficiency:
1) The time for one reciprocating bending stroke of the 22-head bender designed and manufactured by Party B shall be ≤ 5 s;
2) The time for one complete product with 22 bends shall be ≤ 55 s;
3) Each bending head shall be equipped with automatic product positioning and clamping mechanisms, without the need for manual positioning or clamping, in order to improve production efficiency;
4) Each bending head group shall be adjusted by a handwheel, with position locking device. Adjustment shall be convenient, stable and reliable.
5. Product quality:
1) The bent tube shape and dimensions shall conform to Party A's product drawings;
2) The envelope dimensions of the bent tubes shall match the drawing dimensions within ±1 mm. The ends of each row of bends shall be flush, with length deviation Δ ≤ 1 mm for both sides of each row;
3) Tubes shall be straight without minor bends, with straightness error not exceeding 1%;
4) The R region of the aluminum tube bend shall be a smooth and regular arc, without oblique angles, kinks or other abnormal bending. There shall be no obvious concavity on the outer side or noticeable wrinkles on the inner side. The deformation rate of the bent section shall be ≤ 10%, with flat diameter ≥ 7.65 mm and bulged diameter ≤ 8.5 mm. (Deformation rate calculation: ratio of flat or bulged diameter to the original circular tube diameter, i.e. 100 − 100 × D_flat / D0 or 100 × D_bulged / D0 − 100.)
5) The surface of bent aluminum tubes shall be smooth without indentations, burrs or internal wrinkles;
6) Bending pass rate ≥ 99%.
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Important
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5
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Automatic TIG Welding Machine for Evaporator Body:
1. This equipment is mainly used for welding between evaporator body and receiver (or straight tube).
2. Composition: The machine consists of bed, main spindle drive mechanism, torch support and guide rail, pneumatic torch feeding mechanism, tailstock, torch adjustment device, touch screen operation interface, arc shielding sheet metal, and TIG welding control system.
3. Machine bed: Designed with aluminum profiles and welded box structure. Overall length approx. 1600 mm, width approx. 1000 mm, height approx. 1800 mm. Clearance rotation radius in the machine center is 800 mm, and the receiver rotation radius at the tail is 300 mm. The appearance is neat and attractive.
4. Main drive box: Box-welded structure mounted on the bed. The main spindle is driven by a servo motor, which is not affected by welding harmonic interference during high-frequency TIG arc ignition, ensuring very smooth rotation. The motor has sufficient power and torque, and spindle speed is steplessly adjustable. The machine is equipped with a dedicated copper grounding and current transfer structure to protect the rotating bearings.
5. Pneumatic torch feeding mechanism: Adopts pneumatic actuators with reliable structure and quick response. During welding, the torch automatically moves down to the welding position; after completion, the torch automatically returns to its home position.
6. Torch support and fine adjustment mechanism: The support column is fixed on the machine frame, and the torch can be adjusted in three dimensions (up/down, left/right, front/back) via the torch adjuster. The fine adjustment range in left/right and front/back directions is not less than 50 mm, and the fine adjustment range in vertical direction is not less than 50 mm. The mechanism adopts a dovetail slide with locking function to ensure that the position remains unchanged during repeated motion. Compared with other torch adjustment methods, this three-dimensional adjustment allows the torch to be moved and rotated in multiple directions to reach the optimal welding position and achieve the best welding quality. The torch support position on the beam can be manually adjusted along the axis to weld workpieces of different sizes.
7. Electrical control system: The whole machine is controlled by a PLC programmable controller, realizing automatic torch positioning, automatic welding and automatic return, etc. The machine can simulate process parameters and adjust welding parameters.
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6
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Resistance Welding Machine:
1. The resistance welding machine is used for welding between the evaporator body and straight tubes. The complete set mainly consists of welding fixtures, resistance welding control system and transformer.
2. Welding method: resistance welding.
3. Workpiece material: copper–aluminum.
4. Requirements for workpieces to be welded: free from large amounts of oil, rust and other contaminants; consistency of workpieces shall meet automatic welding requirements.
5. The machine adopts a mode in which the workpiece remains stationary while the welding dies move.
6. During welding, the workpiece is placed on the welding dies and the foot switch is pressed. The vertical cylinder automatically clamps the workpiece, and the horizontal cylinder automatically pushes the aluminum tube into the evaporator, completing the whole resistance welding process. After welding, the operator removes the workpiece and the next cycle begins.
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7
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Tube End Cutting Machine:
1. The tube end cutting machine is dedicated equipment for cutting off and removing scrap aluminum tubes at the tail of direct-insertion evaporators. The complete set mainly consists of an adjustment mechanism, cutting die, scrap collection box, and pneumatic control system.
2. Workpiece material and size: Φ8 aluminum tube (plain tube or inner-tooth tube).
3. The machine bed adopts an aluminum profile box design, with the table machined as an integral surface.
4. Cutting die: driven by a large-bore cylinder with four-column guiding structure, featuring quick and reliable response. The cutting die is quenched and hardened.
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Important
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8
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Side Plate Assembly Machine:
1. This equipment is mainly used as an automatic assembly machine for side plates and evaporator body of fin type evaporators. The machine mainly consists of bed, nylon mold and pneumatic pressing mechanism. It is suitable for automatic assembly of evaporators with 50 mm fins.
2. Machine bed: The bed is assembled from aluminum profiles and sheet metal, with overall length 1000 mm, width 1000 mm and height 1600 mm.
3. Nylon mold: Manufactured from PP nylon plates by precision machining according to aluminum tube bend dimensions.
4. Pneumatic pressing mechanism: Driven by a large-bore cylinder and guided by linear guide rails, ensuring high assembly accuracy.
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9
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Elbow Bending Machine:
1. This equipment is used for bending aluminum tubes at the tail of evaporators. The complete set mainly consists of bed and bending wheel.
2. Table size: approx. 1000 × 600 mm.
3. Tube diameter: Φ8 aluminum tube (plain tube or inner-tooth tube).
4. The bed adopts an aluminum alloy profile box design. The table uses a flexible design with an array of threaded holes to meet bending requirements of evaporators with different sizes and shapes.
5. Different models of elbow bending machines shall be designed according to different products and tube shapes. Machines are not interchangeable and belong to dedicated special-purpose equipment.
6. Aluminum tubes are bent by cylinders driving a rack-and-pinion mechanism.
7. Suitable for aluminum tubes with 3–4 bends.
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10
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Water Leak Test Tank:
1. The water leak test tank is a dedicated machine developed by our company for leak testing of oblique-insertion evaporators. The machine has an attractive appearance, is easy to operate and offers high working efficiency, suitable for mass production. The complete set mainly consists of stainless steel water tank, pipe fittings, pressure control system and electrical control system.
2. Tank size (L × W × D): 1200 × 600 × 250 mm.
3. Test pressure: 3.0 MPa.
4. During operation, the fixture is clamped onto the evaporator tube ends manually, and the start button is pressed. The equipment automatically charges air to the test pressure. If no leak is detected within a specified time, the equipment displays "OK" and a green light turns on. The operator then removes the workpiece and fixture. If a leak is detected, the equipment displays "NG", a red light turns on and an alarm sounds.
5. The machine bed adopts an aluminum profile box design and the water tank is made of stainless steel. Overall machine length is approx. 1600 mm, width approx. 2000 mm, height approx. 2000 mm, with a neat and attractive appearance.
6. The system uses a digital pressure sensor connected with PLC to realize automatic leak detection.
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11
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Pneumatic System:
1. The pneumatic system adopts centralized air distribution. A dryer and filter are installed at the main air inlet to ensure clean and dry compressed air.
2. The system consists of FRL unit, solenoid valves, vacuum components and pipelines.
3. Layout of air, water and electrical pipelines shall comply with standards for new equipment. No air leakage is allowed at any connection.
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Important
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12
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Electrical Control System:
1. The PLC shall be equipped with a built-in Ethernet port to enable seamless SLMP communication with MES system or host computer in the future.
2. Servo motors shall adopt absolute-type systems with built-in zero points, high repeatability and no loss of reference after power-off, so homing is not required at start-up, improving efficiency.
3. Servos shall support Ethernet communication, with simple wiring, easy start-up, convenient fault diagnosis and high system flexibility.
4. The touch screen shall have 20–100 recipe groups built in, allowing one-touch switching of product parameters to realize SMED quick changeover.
5. The touch screen shall include visual alarm pages and I/O monitoring to guide fault troubleshooting.
6. The touch screen shall include TPM pages, basic OEE data collection and display, and maintenance reminders.
7. Solenoid valves shall be centrally installed on a valve island in the pneumatic cabinet, with clear identification, high safety and convenient maintenance. All electrical wires and air hoses shall be distinguished by different colors for visual management.
8. The safety protection level shall be high. Hardware measures plus built-in POKA-YOKE error-proofing functions in the program shall be adopted.
9. The equipment appearance shall be refined. Control panels shall use customized aluminum alloy enclosures. Beds and sheet metal parts shall be industrially designed and powder coated.
10. The whole line layout shall adopt a cell line arrangement to reduce handling waste and WIP.
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Important
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13
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Safety Devices:
1. Safety markings:
- All moving parts shall be painted with yellow warning color.
- Warning labels shall be placed at hazardous locations.
- Electrical cabinets and junction boxes shall bear electrical hazard labels.
- Guardrails shall be installed according to Party A's requirements, consistent with Party A's standards.
2. Electrical safety protection:
- Emergency stop buttons shall be provided at operator activity areas.
- Safety guardrails and electrical alarms shall be added at loading and unloading areas.
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Important
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