Power Container Assembly Line

Core Process Flow

1. Intelligent Feeding and Container Pre-Treatment
At the start of the line, a gantry container mobile vehicle is used for material delivery. The vehicle precisely lifts an empty power container onto the slat chain conveyor and then automatically disengages. At the pre-treatment station, workers open and secure a total of eight doors (front and rear) of the container. This ensures the container body remains stable during subsequent movement and provides unobstructed access for internal preparation and automated assembly.

2. Fully Automatic Precision Stack Assembly
● The core of this production line lies in its dual-station stacking robot system:
Automatic Feeding: Workers use a forklift to transfer stacks from the storage area to a dedicated stack frame, enabling material buffering and automatic positioning.
Pickup and Travel: The stacking robot moves to the pickup position and retrieves a stack from the frame using a specialized forking device.

● Layered Assembly:
First Layer Assembly: The robot, carrying the stack, moves into the container and precisely places six stacks into the bottom installation positions.
Second Layer Assembly: The slat chain conveyor moves the container to the next stacking robot station, where a second robot completes the assembly of the six stacks on the upper layer.

3. Flexible Manual Assembly Stations
To address the complex wiring, piping, and fastening requirements inside the container, the line is equipped with multiple human-machine collaboration stations:
● Fastening Station: Workers manually tighten the coupling bolts between the stacks and the container body to ensure mechanical connection strength.
● Pipe Installation Station: Connections for the internal cooling system and ventilation ducts within the container are completed here.
● Electrical Installation Station: Tasks such as routing, plugging, and bundling of high and low-voltage wiring harnesses are carried out here.

4. Quality Inspection and Offline
After assembly, the container moves to the pressure testing station where workers perform airtightness or pressure tests. Upon passing inspection, the container doors are closed. At the end of the line, the gantry container mobile vehicle intervenes again, lifting the finished product off the slat chain conveyor body and transporting it to the next process step or the finished product storage area.

Production Line Advantages

1. High Level of Automation: The combination of gantry cranes and slat chain conveyors solves the logistical challenges of transporting large components; stacking robots replace manual handling of heavy-load stacks, reducing labor intensity.

2. High-Precision Positioning: The robots feature precise travel and positioning capabilities, ensuring repeatable accuracy for stack installation and preventing damage from collisions.

3. Flexible Production: The organic integration of manual stations and automated equipment meets standardized assembly requirements while adapting to the flexibility needed for complex piping and electrical connections.

4. Balanced Takt Time: Through a dual-layer split assembly design, space is utilized effectively, production takt time is optimized, and overall capacity is increased.