Automated production line for automobile horn Product Details

In the field of car audio manufacturing, car horn as a key acoustic component, its assembly accuracy and consistency directly affects the acoustic experience of the car, while the traditional segmented production mode is often faced with process fragmentation, manual intervention, data traceability and other pain points, especially difficult to adapt to the long order cycle, mass production of quality and stability of the demand. In response to this core demand, we developed the automated production line for automotive speakers, realizing the whole process of automated assembly from the T-iron input to the finished product packaging, and becoming the core equipment for the manufacturing of long-cycle and high-volume automotive speakers with high-end design, intelligent control and stable performance.

The production line takes the whole process automation as its core competitiveness, and builds a closed-loop production system of "raw material input-precision assembly-testing and grading-finished product packaging". The starting end is equipped with T-iron automatic loading mechanism, through servo mechanical arm and CCD visual positioning system to achieve accurate gripping and positioning, positioning accuracy of ± 0.02mm, followed by the subsequent completion of the magnetic circuit assembly, voice coil winding, diaphragm lamination, terminal welding and other key processes in turn, the various workstations through the intelligent conveyor system seamlessly, the whole process without human intervention. For the precision requirements of automobile horn assembly, the key stations are equipped with imported servo drive module, which can accurately control the assembly pressure and stroke, for example, the magnetic circuit riveting pressure control accuracy reaches 0.1N, which effectively avoids the assembly deviation caused by manual operation. The terminal finished product packaging link integrates automatic sorting, counting and encapsulation systems, realizing the unmanned operation of the whole process from raw materials to finished products.

High-end design and intelligent control form a multi-dimensional competitive advantage. The structural design adopts aviation-grade aluminum alloy frame and fully enclosed dustproof shell, together with precision machining process, which not only guarantees the rigidity of the whole machine but also improves the texture of the equipment, which meets the needs of high-end manufacturing workshop layout. The operation level is equipped with visualization industrial software, 10-inch touch screen, real-time display of the operating status of each station, production capacity data and fault warning, the staff can complete the parameter setting and process monitoring after simple training, support for the process parameters of the one-key storage, the replacement of the pre-set program directly call. Modular design makes the equipment maintenance more flexible, each functional unit can be disassembled independently for maintenance, which greatly shortens the downtime and increases the comprehensive utilization rate of the equipment to more than 95%.

Quality assurance and data management meet high-end production requirements. The production line is equipped with a multi-station AOI visual inspection system, which detects dimensional accuracy, assembly deviation and appearance defects in real time at key nodes such as magnetic circuit assembly, diaphragm lamination, welding, etc., with an accuracy of 99.8%, and automatically rejects non-conforming products and records the type of defects. The data-based process analysis system collects production data from each station in real time, generates reports on production capacity trend and fluctuation of qualified rate, supports data export and traceability, and helps enterprises optimize the production process. The whole machine has been tested by 1000 hours of continuous operation, and the failure rate is lower than 0.3%. It is stably adapted to the scenarios of long order cycle and mass production, which can improve the efficiency of a single production line by more than 6 times, and the qualified rate of the product is increased from 94% in manual assembly to 99.6%.

The production line is widely adapted to the manufacture of various types of automotive speakers, such as car subwoofers, tweeters, coaxial speakers, etc. It is especially suitable for the long cycle and large-volume order demand of the supporting suppliers of automotive OEMs. Through automation upgrading and intelligent control, it not only reduces 80% labor input, but also guarantees the quality stability, provides core support for the enterprise to build a highly efficient, accurate and traceable production system, and promotes the transformation of the automotive audio manufacturing industry to intelligence and scale.