SECTOR: DOMESTIC APPLIANCES
APPLICATION: assembly and testing of air conditioners
PROBLEM:
The realization of a conditioner assembly and testing line to optimize output of even small and medium volumes and which must be flexible in order to make possible both the simultaneous assembly of two different models and the handling of lots of different sizes in addition to effecting fasf changes in production.
Specifications :
  • space restrictions;
  • variability in assembly times depending on conditioner model;
  • minimum fixed time required for both the vacuum formation and testing, plus the necessity of assembly line feed at a well defined product flow rate;
  • variability in the minimum time required for both the formation of the vacuums and testing, according to the volume of the cooling circuit (that is, the conditioner model).
 

SOLUTION:
The assembly line has been created using System 08 pallet conveyors and basically consists of a central mainline which symmetrically serves 20 assembly bays.
Each bay has a buffer line for the input of pieces for processing, two workstations equipped with rotating platforms, and two buffer lines for the exit of pallets bearing the processed pieces. The buffering possibility reduces the rigidity of the connections between the various operations.
A double transfer then connects the assembly line with both the vacuum carousels and the Freon charges which, together with the testing carousels, use System 2000 overhead dual track conveyors.
The adopted software guarantees plant modularity and flexibility, thus making it possible not only to operate without certain bays but also to have a different side A/side B configurations.

Furthermore, it is possible to have the bays laid out in series, and thus to carry out the operations in sequence, or alternatively in parallel, which means the same operation can be carried out simultaneously in two or more bays.
In addition, the plant has a self-diagnosis system and a production survey system, providing production data by shift, day and month.