A semi-automatic production process for float level switch

Abstract

The present invention provides a semi-automatic production process of a float liquid level switch, which belongs to the technical field of float switch production. It includes the following steps: accessory preparation: injection molding of a float, a baffle and a nut; setting a body with a universal clamping groove; wire harness processing; soldering processing: bending and cutting the legs of the reed switch, welding the reed switch to the wire harness to form a reed switch assembly; assembling the body, nut, washer float and baffle into a combination at one time; glue filling processing: first use the universal clamping groove on the body as the limit clamping position, transport and count each assembly online, fill glue on each assembly, insert, clamp and sort the wire harness online, and pre-check and count the semi-finished product online; baking: bake the semi-finished product once on the online grill, fill glue after baking once, and then bake it twice; finished product detection; laser marking; the production of the float liquid level switch is completed after packaging. The present invention has the advantages of high efficiency and high product quality.

Description

Technical Field

[0001] The invention belongs to the technical field of float opening production, and relates to a semi-automatic production process of a float liquid level switch. Background Art

[0002] The float level switch is smaller, faster, and has a longer service life than general mechanical switches. Compared with electronic switches, it has the characteristics of strong load impact resistance. However, the connection of the conventional float level switch to the motherboard is mainly dominated by wires and conventional connectors. The length and specifications of the wires and connectors are different, the length of the body is different, and the installation interface is different. Because the specifications, lengths and forms of the level float switch are diverse, the complexity of the product production process and the difficulty of the process are increased. It belongs to the processing technology of small-scale and diversified production, resulting in heavy workload in the production process.

[0003] The float level switch is a key component. When the float level switch fails, it often causes dangerous conditions such as equipment shutdown or overflow short circuit tripping. Artificially produced float level switches often cause product failures and poor efficiency due to human misjudgment, mistakes, mixing, etc., especially in today's environment. Changes are as follows:

[0004] 1. There is a shortage of production human resources, and the labor costs of production enterprises are getting higher and higher.

[0005] 2. Customers have higher and higher requirements for quality. When product complaints occur, fines of thousands to tens of thousands of yuan are imposed at any time. The quality risk borne by the factory is too high.

[0006] 3. Customers have increasingly higher requirements for quality and environmental system management, and the quality costs borne by factories are also relatively increasing.

[0007] 4. Prices continue to rise, the price of reed switches continues to rise, and product profits are declining year by year.

[0008] Based on the above reasons, it is necessary to improve production efficiency and reduce production costs. Summary of the invention

[0009] The purpose of the present invention is to provide a semi-automatic production process for a float liquid level switch in view of the above-mentioned problems existing in the prior art. The technical problem to be solved by the present invention is how to improve the efficiency and product quality.

[0010] The object of the present invention can be achieved by the following technical solutions: A semi-automatic production process of a float liquid level switch, characterized in that it includes the following steps:

[0011] A. Accessories preparation: injection molding of floats, baffles and nuts, welding of hardware accessories; setting up a body with a universal clamping groove; preparing the raw materials and purchased parts required for the production of the liquid level float switch, injection molding of floats, baffles, nuts and other accessories by molding machines, and welding of the stainless steel body;

[0012] B. Wire harness processing: complete wire harness peeling and terminal punching, manually insert connector shells, and count and tie the wire harness;

[0013] C. Soldering processing: bend and cut the legs of the reed switch, and weld the reed switch to the wiring harness to form a reed switch assembly; the reed switch is a key component of the liquid level float switch. Since the reed switch is made of glass, it is prone to damage during the processing process. All processing techniques must be based on the highest principle of protecting the reed switch.

[0014] D. Assemble the body, nut, washer float and baffle into an assembly at one time. In the traditional process, it is necessary to pour glue, scrape glue, dry and solidify before assembly. This solution puts the assembly process in front. Compared with the old process, it reduces the processes of threading nuts, washers, pushing nuts and pushing washers. There is no interference from the wiring harness. Large quantities of products can be assembled automatically, which improves the efficiency of assembly positions by at least 50%.

[0015] E. Glue filling processing: First, the universal clamping groove on the main body is used as the limit clamping position, and the clamping tooling is used to complete the clamping of each assembly. Then, each assembly is transported and counted online, and each assembly is filled with glue. The wire harness is inserted, clamped and sorted online, and the semi-finished products are pre-inspected and counted online. In the traditional process, the main body cannot be clamped due to different sizes, and it is also impossible to operate online. In comparison, the product production rhythm speed is accelerated and the error rate of human operation is reduced. An automatic glue filling machine is used to pre-inject 80% epoxy resin glue into the body of the module. Compared with the old manual glue filling process, the advantage of the new process is that the automatic glue filling machine has heating, pressurizing and defoaming functions, and the use of 80% glue volume control can effectively solve the problem of glue overflow during glue baking; due to the use of online clamping operation, the problem of poor switch action limit caused by wire floating due to movement, turnover, vibration or baking is completely avoided, and the consistency of product action function is increased, and the accuracy and yield of the product are improved; pre-inspection of semi-finished products can be carried out, and various automated testing equipment can be added according to product characteristics to completely avoid artificial mixing, installation errors, test errors and other human defects in advance, which not only improves job efficiency and product quality assurance but also reduces the pressure of labor demand.

[0016] F. Baking: The semi-finished product is baked once on the online baking rack, and then glue is added after the first baking, and then baked for the second time. Because the glue in the first gluing is only 80%, and after the automatic glue filling machine defoams, the glue will not overflow from the body during the curing process. The glue filling and baking in two times can not only avoid glue overflow, but also directly eliminate the glue scraping process in the traditional process.

[0017] G. Finished product testing;

[0018] H. Laser marking;

[0019] I. The production of the float level switch is completed after packaging.

[0020] Furthermore, in the step E, when the assembly is filled with glue, the amount of epoxy resin glue must be controlled to account for 80% of the inner cavity of the body to avoid glue overflow.

[0021] Furthermore, the universal clamping groove is an annular inner recessed portion of the outer wall surface in the middle portion of the body.

[0022] Compared with traditional technology, this solution has the following advantages:

[0023] 1. Improved production efficiency: Simplified multiple original production process steps, avoided the time loss of repeated turnover of materials and personnel, realized test automation, improved overall production speed, and achieved the ideal effect of lean production.

[0024] 2. Avoid mistakes: Avoid mistakes caused by human factors, including manual mixing, installation errors, wire pulling, testing errors, product dropping, etc.

[0025] 3. Optimized product quality: Glue-filling and line-fixing production improves the consistency of product functions, test automation realizes accurate function determination, and new test stations can be added at any time, providing future quality expansion.

[0026] 4. Reduce costs, including:

[0027] 1) Avoid the adverse costs caused by bad process material loss.

[0028] 2) Avoid the rework costs caused by product rework.

[0029] 3) Reduce the labor cost of manpower requirements.

[0030] 4) Reduced the workload of employees, created conditions for retaining employees, and reduced the training costs of employee turnover.

[0031] 5) Reducing the customer complaint rate reduces the customer service costs caused by customer complaints.

[0032] 5. Reduce risks, including:

[0033] 1) Reduce the risk of penalties due to customer complaints.

[0034] 2) Reduce the risk of default due to delayed delivery.

[0035] 3) It reduces the workload of employees, creates conditions for retaining employees, and avoids the risk of mistakes due to employee turnover.

[0036] 4) Improved the future development potential of the industry.

[0037] 5) The production automation ratio has been increased and the modular production model has been adopted, creating conditions for unmanned factories in the future.

[0038] 6) Improve product quality, reduce costs, reduce customer complaints, increase production capacity, and improve customer satisfaction, creating survival conditions for the industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a flow chart of the semi-automatic production process of float level switch.

[0040] Figure 2 It is a schematic diagram of the three-dimensional structure of the body with a universal clamping groove.

[0041] In the figure, 1. Universal clamping groove. DETAILED DESCRIPTION

[0042] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solution of the present invention, but the present invention is not limited to these embodiments.

[0043] like Figure 1 As shown, the process includes the following steps

[0044] Accessories preparation: injection molding float, baffle and nut, welding hardware accessories; set the body with universal clamping groove 1, such as Figure 2 As shown in the figure, the raw materials and purchased parts required for the production of the liquid level float switch are prepared, the float, baffle, nut and other accessories are processed by injection molding machine, and the stainless steel body is welded;

[0045] Wire harness processing: complete wire harness peeling and terminal punching, manually insert connector shells, and count and tie the wire harness;

[0046] Soldering processing: bend and cut the legs of the reed switch, and weld the reed switch to the wiring harness to form a reed switch assembly; the reed switch is a key component of the liquid level float switch. Since the reed switch is made of glass, it is prone to breakage during the processing process. All processing techniques must be based on the highest principle of protecting the reed switch.

[0047] The main body, nut, washer float and baffle are assembled into an assembly at one time; in the traditional process, glue pouring, glue scraping, drying and curing are required before assembly. This solution puts the assembly process in front. Compared with the old process, it reduces the processes of threading nuts, washers, pushing nuts and pushing washers. There is no interference from the wiring harness, and large quantities of products can be assembled automatically, which improves the efficiency of the assembly position by at least 50%.

[0048] Glue filling process: first use the universal clamping groove on the main body as the limit clamping position, use the clamping tooling to complete the clamping of each assembly, then transport and count each assembly online, fill each assembly with glue, plug, clamp and sort the wire harness online, and pre-inspect and count the semi-finished products online; in the traditional process, the main body cannot be clamped due to different sizes, and it is also impossible to operate online. In comparison, it speeds up the product production rhythm and reduces the error rate of human operation. An automatic glue filling machine is used to pre-inject 80% epoxy resin glue into the body of the module. Compared with the old manual glue filling process, the advantage of the new process is that the automatic glue filling machine has heating, pressurizing and defoaming functions, and the use of 80% glue volume control can effectively solve the problem of glue overflow during glue baking; due to the use of online clamping operation, the problem of poor switch action limit caused by wire floating due to movement, turnover, vibration or baking is completely avoided, and the consistency of product action function is increased, and the accuracy and yield of the product are improved; pre-inspection of semi-finished products can be carried out, and various automated testing equipment can be added according to product characteristics to completely avoid artificial mixing, installation errors, test errors and other human defects in advance, which not only improves job efficiency and product quality assurance but also reduces the pressure of labor demand.

[0049] Baking: The semi-finished product is baked once on the online baking rack, and then glue is added after the first baking, and then baked for the second time; because the glue in the first gluing is only 80%, and after the automatic glue filling machine defoams, the glue will not overflow from the body during the curing process. The two-step gluing and baking can not only avoid glue overflow, but also directly eliminate the glue scraping process in the traditional process.

[0050] Finished product testing;

[0051] Laser marking;

[0052] After packaging, the production of the float level switch is completed.

[0053] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A semi-automatic production method for a float level switch, characterized in that: The steps include: A. Accessories preparation: injection molding of float, baffle and nut, welding of hardware accessories; setting of the body with universal clamping groove; B. Wire harness processing: complete wire harness peeling and terminal punching, manually insert connector shells, and count and tie the wire harness; C. Soldering process: bend and cut the legs of the reed switch, and weld the reed switch to the wiring harness to form a reed switch assembly; D. Assemble the body, nut, washer float and baffle into a combined unit at one time; E. Glue filling process: first use the universal clamping groove on the main body as the limit clamping position, use the clamping tooling to complete the clamping of each assembly, then transport and count each assembly online, fill each assembly with glue, insert, clamp and sort the wire harness online, and pre-check and count the semi-finished products online; F. Baking: Baking the semi-finished product once on the online baking rack, then re-baking it for the second time after the first baking; G. Finished product testing; H. Laser marking; I. The production of the float level switch is completed after packaging.

2. According to claim 1, a semi-automatic production method of a float liquid level switch is characterized in that: In the step E, when the assembly is filled with glue, the amount of epoxy resin glue must be controlled to account for 80% of the inner cavity of the body to avoid glue overflow.

3. A semi-automatic production method of a float liquid level switch according to claim 1 or 2, characterized in that: The universal clamping groove is an annular inner concave portion of the outer wall surface in the middle part of the body.

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