JCXLC Condenser Production Solution: Efficient and Intelligent Production Line for Capacity Upgrade

1. Introduction: Building an Industry-Leading Condenser Production Base

As a company specializing in the development and manufacturing of heat exchange equipment, Jinchun Machinery continues to drive technological innovation. We are committed to providing customers with efficient, energy-saving, and environmentally friendly condenser production solutions. In response to the growing demand for high-quality condensers in the market, Jinchun introduces the Daily 1000-Piece Condenser Intelligent Production Line. This line integrates various self-developed automation equipment, covering the entire process from raw material processing to final product assembly, significantly enhancing production efficiency and product competitiveness.

 

2. Core Equipment Configuration: Precisely Matching Production Needs

This solution selects five high-performance machines to build a standardized production line, covering the five key stages of condenser manufacturing: straightening, pipe bending, cutting, welding, and post-welding repair. 

1. Pneumatic Straightening Machine (1-1.8mm)

Function: Core equipment for raw material pre-processing 

Technical Parameters: Suitable for metal tubes with diameters from 1-1.8mm, using pneumatic drive for rapid straightening and eliminating material deformation errors. 

Capacity Performance: Single machine processes up to 2000 meters per day, providing high-precision raw materials for subsequent processes.

 

2. CNC Pipe Bending Machine

Function: Specialist for complex pipe forming 

Technical Highlights: Supports multi-angle, multi-radius pipe bending programming, equipped with a 380V-50Hz power system, with bending precision of ±0.5°. 

Application: Used for forming U-tube and serpentine pipes for condensers, compatible with various materials including copper, aluminum, and Bondi tubes.

 

3. Bondi Pipe Cutting Machine

Function: Automated cutting workstation 

Efficiency Advantage: Designed for a production capacity of 1000 condensers per day, this machine can cut 500-700 pieces per day with smooth, burr-free edges. 

Energy-saving Feature: Air compressor pressure requirement is only 0.6-0.8Mpa, reducing energy consumption costs.

 

4. Tube Evaporator Welding Machine (2-3 Units Configuration)

Function: High-efficiency welding solution 

Core Parameters: 15KW high-power output, capable of producing 1000-1500 condensers per shift, with a welding speed of 20m/min. 

Quality Control: Equipped with a PLC-based intelligent temperature control system to ensure uniform and strong weld seams, reducing the risk of faulty welds.

 

5. Post-Welding Repair Machine

Function: Precision repair station 

Application: Used for secondary repairs of welding defects or blind spots, equipped with fine-tuning positioning devices to improve welding point correction efficiency by 30%.

 

3. Process Flow: Full-Link Automation Coordination

Step 1: Raw Material Pre-processing

The pneumatic straightening machine performs initial straightening on metal tubes, ensuring material straightness error is less than 0.2mm, laying the foundation for high-precision pipe bending. 

Step 2: 3D Pipe Bending

The CNC pipe bending machine completes complex shapes such as U-tubes and spiral pipes, with bending radii accurately controlled from R5 to R20mm. 

Step 3: Intelligent Cutting

The Bondi pipe cutting machine uses laser positioning technology to achieve precise tube cutting lengths (±1mm error), simultaneously performing end chamfering. 

Step 4: Fully Automated Welding Production Line

Two tube evaporator welding machines form a welding matrix, working with a vision recognition system to complete automated welding of fins and tubes, with weld strength ≥90% of the base material. 

Step 5: Quality Inspection and Repair

The post-welding repair machine addresses welding defects, and with the integration of eddy current testing, 100% online inspection is performed, ensuring a defect rate of less than 0.3%.

 

4. Technical Advantages: Four Highlights for Cost Reduction and Efficiency Improvement

Space-Saving Design

The entire line features a modular layout, reducing the occupied area by 40% compared to traditional production lines, making it suitable for quick deployment in small and medium-sized factories. 

Efficient Human-Machine Collaboration

The PLC touch screen allows for one-touch operation, requiring only 2-3 people per shift to complete full process control, reducing labor costs by 60%. 

Energy-Efficient Optimization

The integrated variable frequency drive system automatically adjusts power output based on load, reducing overall energy consumption by 25%. 

Full-Process Quality Traceability

The MES system records processing parameters for each batch, enabling rapid problem identification and process optimization.

 

5. Investment Return Analysis

Based on the production of 1000 condensers per day, the financial estimates are as follows: 

Initial Investment: Total equipment cost is approximately 1.5 million RMB 

Operating Costs: Electricity cost is around 800 RMB/day, consumables cost is around 300 RMB/day 

Expected Revenue: With an average market price of 80 RMB per condenser, daily revenue is 80,000 RMB, and the payback period is approximately 6 months.

 

6. Service Commitment: Jinchun One-Stop Support

Installation and Commissioning: Senior engineers will be on-site for 7×24-hour installation guidance. 

Skill Training: Free equipment operation and maintenance training.

After-Sales Support: Core components are covered by a 3-year warranty, and lifelong technical support is provided. 

Upgrade Service: Free software system upgrades.

 

7. Conclusion: Partner with Jinchun for a Win-Win Future

This solution deeply integrates intelligent manufacturing concepts, providing condenser production enterprises with a cost-effective, highly reliable, and easily expandable modern production line. Jinchun Machinery will continue to focus on the heat exchange field, driving technological innovation with craftsmanship to help partners seize the market opportunity. 

Contact Jinchun Machinery Equipment Co.,Ltd

Tel: +86 15015830219

Email: [email protected]

Website: www.jinchunxlc.com