The efficiency improvement of the automation transformation of the chiller production line is usually 25% to 50%, and the specific value is affected by the automation foundation, workstation redundancy, and equipment integration before the transformation.
1, The components of improving core efficiency
(1) Optimization of workstation operation efficiency
Replace manual repetitive assembly and testing stations (such as copper tube expansion, refrigerant injection, electrical wiring), eliminate manual operation cycle fluctuations and errors, and compress single station operation cycle by 15% to 30%; Note: The automation transformation of high-risk processes such as refrigerant injection and high-pressure leakage detection must be operated by personnel with special equipment operation qualifications, and the upper limit of safety pressure must comply with the requirements of GB/T 18430.1-2008 "Steam Compression Circulating Cold Water (Heat Pump) Units".
Integrate the loading, unloading, and transportation processes of the assembly line, shorten the waiting and connection time between workstations, and improve the efficiency of the line flow by 10% to 20%. (2) Quality linkage and efficiency improvement
The automation coverage of online testing stations (such as energy efficiency testing and insulation resistance testing) has been improved, reducing rework hours caused by manual missed/false detections, indirectly increasing the overall production efficiency by 8% to 12%. 2, Key influencing conditions for efficiency improvement
(1) Pre renovation foundation: The efficiency improvement of a fully manual production line is 10% to 15% higher than that of a semi automated workstation mixed line. (2) Integration degree of transformation: The efficiency improvement of the whole line joint debugging transformation (including data interconnection between equipment) is 10% to 20% higher than that of single station transformation. 3, Industry reference range
The automation renovation projects publicly announced by mainstream domestic chiller manufacturers from 2022 to 2023 have generally improved comprehensive efficiency by 32% to 47%, corresponding to a reduction of 18% to 35% in the production cycle of a single unit.
