TV Horn Automation Production Line Product Details

In the field of TV audio manufacturing, square magnetic circuit speaker as a core acoustic component, its assembly accuracy directly determines the fidelity of TV sound quality and playback stability, while the traditional manual assembly mode is often faced with square magnetic circuit positioning deviation, misalignment of multiple parts assembly, lack of consistency and other pain points, it is difficult to adapt to the mass production of high-grade TV products needs. In view of the assembly characteristics of TV square magnetic circuit speakers, we developed the TV speaker automation production line came into being, to realize the whole process of automation from T-iron input to the assembly of the transfer line, to meet the needs of high-grade TV speakers mass production with the core advantages of "high precision, high efficiency, high compatibility".

The production line takes the assembly process of TV square magnetic circuit speaker as the core, and builds an exclusive production system of "multi-part precise assembly + full-process automation". For the assembly characteristics of square magnetic circuit, it adopts partitioned intelligent loading system, T-iron is accurately gripped by servo mechanical arm with CCD visual positioning, and the positioning accuracy is ±0.02mm; the magnet carries anti-magnetic interference vibration plate to feed the material, and the magnetic circuit calibration module ensures the correct polarity; the bracket, voice coil, elastic wave and other components are synchronously transported by customized fixtures to achieve parallel loading of multi-materials and accurate alignment. The core assembly link adopts imported servo drive technology to accurately control the assembly pressure and displacement for precision processes such as drum paper fitting, with pressure control accuracy up to 0.1N, which completely solves the problems of square magnetic circuit offset and uneven drum paper fitting in manual assembly, and realizes the seamless connection of the whole process from the T-iron, magnet, bracket, voice coil, elastic wave, drum paper, and transfer line.

High adaptability and efficient debugging design to meet the needs of TV speakers with multiple specifications. The production line is equipped with modularized workstation structure, for different sizes of TV speakers from 32 inches to 85 inches, customized fixtures and assembly modules can be changed quickly, and with the parameterized control system, key parameters such as loading speed and assembly stroke can be adjusted through the touch screen, and the changeover debugging time can be shortened from the traditional manual line of 2 hours to less than 30 minutes. In view of the unique structure of the square magnetic circuit of TV speakers, the production line has developed an exclusive magnetic circuit positioning calibration algorithm, which, together with the multi-dimensional visual inspection unit, ensures that the coaxiality error of the square magnetic circuit with the voice coil and the bracket can be controlled within 0.03mm, which is perfectly adapted to the assembly needs of different models of TV speakers with square magnetic circuits.

Production efficiency and product quality to achieve a double breakthrough. Efficiency improvement, the traditional manual assembly can only complete 150-200 sets per hour per person, the production line through the parallel operation of multiple stations and process optimization, the production capacity can reach more than 1,200 sets per hour, the efficiency of 6-8 times, a single production line can reduce the 80% labor input, significantly reducing labor costs and management costs. In terms of quality assurance, the key stations integrate AI visual inspection and force control sensing system, real-time detection of magnetic circuit assembly precision, drum paper fitting flatness, turn line welding quality and other key indicators, non-conforming products are automatically sorted out and defect types are recorded, the product qualification rate has increased from 92% in manual assembly to more than 99.6%. For the sound quality requirements of high-end TV products, the production line also integrates the magnetic flux detection module to ensure the consistency of the magnetic field strength of each speaker and guarantee the stability of TV audio playback.

Starting from the demand of mass production, the production line is equipped with an intelligent production management system, which collects real-time data such as production capacity, qualification rate, equipment operation status, etc., supports the automatic generation and export of production reports, and helps the enterprise to realize the transparent control of the production process. The whole machine adopts a fully enclosed dustproof design, and with the automatic lubrication system, the failure rate is less than 0.5% for 8 hours of continuous operation, which is stably adapted to the long-term mass production scenario of high-grade TV speakers. Whether it is the large-scale production of smart TV manufacturers, or the order delivery needs of audio supporting enterprises, the production line can provide customized solutions, with exclusive process design and stability, become the core equipment for TV speaker manufacturers to improve quality and efficiency.