Air conditioner production, operation and maintenance system and production method

Abstract

A production, operation and maintenance system and production method for an air conditioner are disclosed. [Solution] A control system communicates with a general-purpose heat exchanger production system, an indoor unit production system, an outdoor unit production system, a material storage system, a packaging system, and a conveying system. The control system is configured to control the conveying system to convey materials, control the indoor heat exchanger fin production unit and the general-purpose production unit to produce indoor heat exchangers, control the indoor unit production system to produce indoor units using the indoor heat exchangers and indoor unit materials, control the outdoor heat exchanger fin production unit, the general-purpose production unit, and the bending unit to produce outdoor heat exchangers, and control the outdoor unit production system to produce outdoor units using the outdoor heat exchangers and outdoor unit materials.

Description

[Technical Field]

[0001] Some embodiments of the present application relate to the technical field of air conditioner production systems, and more particularly to systems and methods for producing, operating, and maintaining air conditioners. [Background technology]

[0002] Currently, air conditioner production systems include an indoor unit production line and an outdoor unit production line, with the indoor unit production line including the production of indoor heat exchangers and the outdoor unit production line including the production of outdoor heat exchangers. If the indoor unit production line and the outdoor unit production line were to have indoor and outdoor heat exchanger production units installed respectively, the spatial layout of the production system would be large and the installation costs would be high. Summary of the Invention

[0003] Some embodiments of the present application provide a production, operation, and maintenance system for an air conditioner, which includes: The system includes a general-purpose heat exchanger production system, an indoor unit production system, a bending unit, an outdoor unit production system, a material storage system, a packaging system, a conveying system, and a control system; The heat exchanger general-purpose production system includes: an indoor heat exchanger fin production unit configured to produce indoor heat exchanger fins; an outdoor heat exchanger fin production unit configured to produce outdoor heat exchanger fins; a plurality of general-purpose heat exchanger production units configured to produce unfolded outdoor heat exchangers using the outdoor heat exchanger fins and heat exchanger material, and to produce indoor heat exchangers using the indoor heat exchanger fins and heat exchanger material; the indoor unit production system includes a plurality of indoor unit production units configured to produce indoor units using the indoor heat exchanger and indoor unit materials, the folding unit is configured to fold an unfolded outdoor heat exchanger onto the outdoor heat exchanger; the outdoor unit production system includes a plurality of outdoor unit production units configured to produce outdoor units using the outdoor heat exchanger and outdoor unit materials, the material storage system is configured to store the heat exchanger material, the indoor unit material, and the outdoor unit material; the packaging system is configured to receive and package the indoor unit and the outdoor unit; the conveying system is configured to convey the heat exchanger materials to the heat exchanger general-purpose production system, convey the indoor unit materials to the indoor unit production system, convey the outdoor unit materials to the outdoor unit production system, and convey packaging materials and the indoor units and outdoor units to the packaging system, and includes an overhead crane system; The overhead crane system includes: a rail, a portion of which is located above the heat exchanger general-purpose production system, the indoor unit production system, the outdoor unit production system, and the material storage system; an overhead crane located on the rail and including a gripping device and a position sensing device; the control system communicates with the heat exchanger general-purpose production system, the indoor unit production system, the outdoor unit production system, the material storage system, the packaging system, and the conveying system, and is configured to control the conveying system to convey materials, control the indoor heat exchanger fin production unit and the general-purpose production unit to produce indoor heat exchangers, control the indoor unit production system to produce indoor units using the indoor heat exchangers and indoor unit materials, control the outdoor heat exchanger fin production unit, the general-purpose production unit, and the bending unit to produce outdoor heat exchangers, control the outdoor unit production system to produce outdoor units using the outdoor heat exchangers and outdoor unit materials, and control the packaging system to package the materials and the indoor units and outdoor units; the indoor unit production system and the outdoor unit production system are arranged in parallel between the heat exchanger general-purpose production system and the material storage system, The rail is Overhead crane standby rail section, a material rail section positioned above the material storage system; a heat exchanger rail section positioned above the heat exchanger general production system; an indoor unit rail section located above the indoor unit production system; an outdoor unit rail section located above the outdoor unit production system; a packaging rail section positioned above the packaging system; a first rail section connecting the material rail section and the heat exchanger rail section and positioned between the indoor unit rail section and the outdoor unit rail section; a second rail section connecting the heat exchanger rail section and the indoor unit rail section; a third rail section connecting the first rail section and the indoor unit rail section; a fourth rail section connecting the indoor unit rail section and the overhead crane standby rail section; a fifth rail section connecting the first rail section and the outdoor unit rail section; a sixth rail section connecting the packaging rail section and the overhead crane standby rail section; a seventh rail section connecting the material rail section and the packaging rail section; the overhead crane is configured to travel up to the material rail section, grab the heat exchanger material, reach the heat exchanger rail section via the first rail section, release the heat exchanger material to the heat exchanger general-purpose production system, and then reach the fourth rail section via the second rail section and the indoor unit rail section; the overhead crane is configured to travel up to the material rail section, grab the indoor unit material, reach the indoor unit rail section via the first rail section and the third rail section, release the indoor unit material to the indoor unit production system, and then reach the fourth rail section; the overhead crane is configured to travel up to the material rail section, grab the outdoor unit material, reach the outdoor unit rail section via the first rail section and the fifth rail section, release the outdoor unit material to the outdoor unit production system, and then reach the sixth rail section; the material storage system is configured to store packaging material; the packaging system is located below a sixth rail section of the conveying system, and the material rail section and the sixth rail section are connected via a seventh rail section; The overhead crane of the transport system is configured to travel up to the material rail section to grasp the packaging material, release the packaging material onto the packaging system when it reaches above the packaging system via the seventh rail section, and then reach the overhead crane waiting rail section via the sixth rail section.

[0004] Some embodiments of the present application provide a method for producing an air conditioner by a production, operation, and maintenance system for an air conditioner, the method comprising: Acquiring air conditioner demand information; determining a production process based on the air conditioner demand information; controlling the operating states of the heat exchanger general-purpose production system, the indoor unit production system, and the outdoor unit production system according to the production process; when producing outdoor units in the production process, controlling the outdoor heat exchanger fin production unit, the general-purpose production unit, and the bending unit to produce outdoor heat exchangers, the outdoor unit production system producing outdoor units; when producing indoor units in the production process, controlling the indoor heat exchanger fin production unit and the general-purpose production unit to produce indoor heat exchangers, the indoor unit production system producing indoor units; Based on the air conditioner demand information, the required number of indoor units and the required number of outdoor units corresponding to the model of air conditioner to be produced are determined, and the number n of indoor heat exchangers to be continuously produced is determined, where n is a natural number. Controlling the general-purpose heat exchanger production system to first produce one outdoor heat exchanger and supply it to the outdoor unit production system, and then producing n indoor heat exchangers and supply them to the indoor unit production system; If the number of indoor units reaches the required number of indoor units but the number of outdoor units does not reach the required number of outdoor units, the production process is changed so that the general-purpose heat exchanger production system is controlled to produce outdoor heat exchangers and supply them to the outdoor unit production system; If the number of outdoor units reaches the required number of outdoor units but the number of indoor units does not reach the required number of indoor units, changing the production process to control the general-purpose heat exchanger production system to produce indoor heat exchangers and supply them to the indoor unit production system; Determining the quantity n of indoor heat exchangers to be continuously produced is Determine the time t3 for producing the indoor units and the time t4 for producing the outdoor units based on the model of the air conditioner to be produced, divide the time t4 by the time t3, and then convert the result into an integer to determine n; Alternatively, the number n of indoor heat exchangers to be continuously produced may be set to the number n of indoor units included in one set of air conditioning system, If the production process is to produce an outdoor heat exchanger, control the outdoor heat exchanger fin production unit to produce the outdoor heat exchanger fin, the tube bending unit of the general-purpose production unit cuts the tube at a first cutting operation position, the operating frequency of the tube expanding unit of the general-purpose production unit is a first frequency, and the bending unit bends the unbent outdoor heat exchanger; If the production process is to produce an indoor heat exchanger, control the indoor heat exchanger fin production unit to produce the indoor heat exchanger fin, the tube bending unit of the general production unit cuts the tube at the second cutting operation position, the operating frequency of the tube expanding unit of the general production unit is set to the second frequency, and the bending unit does not operate; the second frequency is less than or equal to the first frequency; Obtaining air conditioner demand information is acquiring an order and acquiring air conditioner demand information based on the order; and / or predicting air conditioner demand information for future time periods based on historical data; an overhead crane of the transport system identifying a material storage location and loading the material; the overhead crane identifies the location of a target unit shelf and transfers the material to the target unit shelf; detecting the quantity of material on the unit shelf, and controlling the conveyance system to convey the material when the quantity of the material falls below a threshold; When the detection result of the detection unit is unacceptable, the conveying system conveys the material before the detection unit, and reproduces the material before the detection unit. detecting the part with a detection unit in the production system; If the detection unit detects a rejected part, outputting the rejected part from the production process via a rejected part conveying line and transmitting reject information to the control system; the control system responding to the rejection information to instruct a transport system to replenish production materials for an upstream process associated with the detection unit; After the planned production quantity of the current production process is completed, a replenishment production process is initiated to reproduce the parts corresponding to the rejected parts using the replenished production materials; the conveying system transmits conveyed material information to the control system; The end plate information creation unit of the heat exchanger general production system creates a unique identifier of each end plate as end plate information on the end plate, and the control system acquires the end plate information; A pallet information creation unit of the indoor unit production system or the outdoor unit production system creates a unique identifier for each pallet as pallet information on the pallet, and the control system acquires the pallet information; The control system associates the end plate information, pallet information, and transported material information, and records production product information and production process information; The control system transmits the transported material information to an end plate information creation unit, and the end plate information creation unit forms the material information and a unique identifier as end plate information and creates it on the end plate; Detecting operating status information of the production unit equipment; Determining or predicting equipment failure based on the operating state information; Controlling the lighting equipment of the production unit so that it is always turned off; When it is determined or predicted that a production unit facility has failed, the unit lighting facility corresponding to the production unit is turned on.

[0005] In order to more clearly describe some embodiments of the present application or the technical solutions of the prior art, the following briefly introduces drawings necessary for describing the embodiments or the prior art. Obviously, the drawings described below are some embodiments of the present application, and those skilled in the art can derive other drawings based on these drawings without any creative efforts. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a schematic layout diagram of an air conditioner production, operation, and maintenance system provided by some embodiments of the present application. [Figure 2] 1 is a schematic diagram of a generalized heat exchanger production system provided by some embodiments of the present application. FIG. [Figure 3] 1 is a schematic diagram of an indoor unit production system provided by some embodiments of the present application. [Figure 4] 1 is a schematic diagram of an outdoor unit production system provided by some embodiments of the present application. [Figure 5] 1 is a schematic diagram of a packaging system provided by some embodiments of the present application. [Figure 6] 1 is a schematic diagram of a system architecture provided by some embodiments of the present application. [Figure 7] 1 is a schematic diagram of an overhead crane system provided by some embodiments of the present application. [Figure 8]1 is a flowchart of a method for producing an air conditioner according to some embodiments of the present application. [Figure 9] FIG. 10 is a schematic diagram of some embodiments of the present application providing an air conditioning detection unit for modifying a production process when a failure is detected. [Figure 10] 1 is a partial structural view of a fin insertion / removal device provided by some embodiments of the present application. [Figure 11] 1 is a position diagram of a lifting support plate provided in some embodiments of the present application in a material storage state. [Figure 12] 1 is a position diagram of a lifting support plate provided in some embodiments of the present application in a material removal state. [Figure 13] 1 is a structural diagram of a lifting support plate provided by some embodiments of the present application. [Figure 14] FIG. 1 is a diagram illustrating a configuration of a downline robot provided by some embodiments of the present application. [Figure 15] FIG. 1 is a diagram illustrating the configuration of a downline jig. [Figure 16] 1 is a structural diagram of a second downline gripping member provided in some embodiments of the present application. FIG. [Figure 17] FIG. 17 is an enlarged view of part A in FIG. [Figure 18] FIG. 2 is a partial structural view of the end plate mounting equipment. [Figure 19] FIG. 10 is a diagram showing the fin stack being transported on the end plate mounting fixture. [Figure 20] FIG. 10 is a diagram illustrating the configuration of an end plate mounting robot. [Figure 21] FIG. 21 is a schematic diagram of the connection at part B in FIG. 20. [Figure 22] FIG. 10 is a diagram showing the end plate jig gripping the end plate member. [Figure 23] FIG. 2 is a diagram illustrating the configuration of a heat exchanger. [Figure 24] FIG. 1 is a diagram illustrating the configuration of nitrogen filling equipment. [Figure 25] FIG. 1 is a diagram illustrating the configuration of a pipe insertion robot. [Figure 26] FIG. 2 is a diagram illustrating the configuration of a pipeline gripping chuck. [Figure 27]This is part 1 of the connection diagram between the nitrogen-filled docking component and the piping component. [Figure 28] 24 is a cross-sectional view taken along CC in FIG. 23. [Figure 29] This is the second diagram of the connection between the nitrogen-filled docking component and the piping component. [Figure 30] FIG. [Figure 31] FIG. 1 is a block diagram of a heat exchanger painting station according to some embodiments. [Figure 32] FIG. 1 is a diagram of an indoor heat exchanger according to some embodiments. [Figure 33] 1 is a diagram of a fin configuration according to some embodiments. [Figure 34] FIG. 2 is a block diagram of a capsule according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0007] The following clearly and completely describes the technical solutions of the embodiments of the present application with reference to the drawings of the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all of the embodiments. Based on the embodiments of the present application, all other embodiments that a person skilled in the art can obtain without any creative efforts fall within the scope of protection of the present application.

[0008] In the description of this application, orientations or positional relationships indicated by terms such as "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," and "outside" are based on orientations or positional relationships shown in the drawings, and are intended to facilitate explanation and simplify the description of this application, and do not indicate or imply that a device or element must have a particular orientation or be configured and operated in a particular orientation, and should not be understood as a limitation on this application.

[0009] The terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or to implicitly designate the number of technical features being presented. Thus, a feature qualified by "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise specified, "plurality" means two or more.

[0010] In the description of this application, unless otherwise clearly specified and limited, the terms "attached," "connected," and "coupled" should be interpreted broadly, and may refer to, for example, a fixed connection, a detachable connection, or an integral connection, a mechanical connection, an electrical connection, a direct connection, an indirect connection via an intermediate medium, or a connection between two elements. Those skilled in the art can understand the specific meanings of the above terms in this application according to specific circumstances.

[0011] In some embodiments of the present application, unless otherwise expressly specified and limited, a first feature being "above" or "below" a second feature can include direct contact between the first and second features, or can include contact between the first and second features via another feature between them rather than direct contact. Furthermore, a first feature being "above," "above," or "on top" of a second feature can include the first feature being directly above and diagonally above the second feature, or simply indicates that the horizontal height of the first feature is higher than that of the second feature. A first feature being "below," "below," or "on the bottom" of a second feature can include the first feature being directly below and diagonally below the second feature, or simply indicates that the horizontal height of the first feature is lower than that of the second feature.

[0012] The following disclosure provides many different embodiments or examples for realizing different structures of some embodiments of the present application. To simplify the disclosure of some embodiments of the present application, the following describes specific example components and configurations. Of course, these are merely examples and are not intended to limit some embodiments of the present application. Furthermore, some embodiments of the present application may refer to repeated reference numerals and / or characters in different examples; this repetition is for purposes of simplicity and clarity and does not in itself indicate a relationship between the various embodiments and / or configurations discussed. Furthermore, while some embodiments of the present application provide examples of various specific processes and materials, those skilled in the art may recognize the application of other processes and / or the use of other materials.

[0013] In some embodiments, as shown in FIGS. 1 and 6 , an air conditioner production, operation, and maintenance system 100 includes a heat exchanger general-purpose production system 101, an indoor unit production system 102, an outdoor unit production system 103, a material storage system 105, a conveying system 108, and a control system 106. In some embodiments, the heat exchanger general-purpose production system 101 is configured to produce heat exchangers. As shown in FIG. 2 , the heat exchanger general-purpose production system 101 includes an indoor heat exchanger fin production unit 1011, an outdoor heat exchanger fin production unit 1012, and a plurality of heat exchanger general-purpose production units 1013. The indoor heat exchanger fin production unit 1011 is configured to produce indoor heat exchanger fins. The outdoor heat exchanger fin production unit 1012 is configured to produce outdoor heat exchanger fins. Since the specifications of the indoor heat exchanger fins and the outdoor heat exchanger fins are different, the fin production unit is divided into an indoor heat exchanger fin production unit 1011 and an outdoor heat exchanger fin production unit 1012. The fin specifications may include, for example, the fin length and the spacing between the fin holes.

[0014] 2 , the heat exchanger general-purpose production unit 1013 includes a tube bending unit 1311, the tube bending unit 1311 including a first cutting position and a second cutting position, the first cutting position configured to cut the outdoor heat exchanger tubes and the second cutting position configured to cut the indoor heat exchanger tubes. In some embodiments, the heat exchanger general-purpose production unit 1013 includes a tube expanding unit 1312, the operating frequencies of the tube expanding unit 1312 including a first frequency and a second frequency, the first frequency being used to produce the outdoor heat exchanger and the second frequency being used to produce the indoor heat exchanger. In some embodiments, the plurality of heat exchanger general-purpose production units 1013 are configured to produce an unbent outdoor heat exchanger using the outdoor heat exchanger fins and heat exchanger material, and to produce an indoor heat exchanger using the indoor heat exchanger fins and heat exchanger material.

[0015] In some embodiments, as shown in FIG. 2 , the starting units are an indoor heat exchanger fin production unit 1011 and an outdoor heat exchanger fin production unit 1012, which are the starting points for heat exchanger production and are used to produce the heat dissipation fins used in indoor and outdoor units, respectively. An end plate information creation unit 1017 creates a unique identifier, typically in the form of an RFID (radio frequency identification) tag, on the end plate of the heat exchanger, which is used to track and manage the entire production process. The end plate information creation unit 1017 is used to create the unique identifier for each end plate as end plate information on the end plate. This end plate information serves as the source of identity information for the heat exchanger and even for the completed unit to be assembled in the future, and is the starting point of the entire information tracking chain.

[0016] As shown in Figure 2, the main production process follows the following logical order: The tube insertion unit 1313 stacks the produced fins and inserts pipes, such as copper pipes, into the fins. The tube bending unit 1311 bends and shapes the pipes to meet different heat exchanger design requirements. The tube expansion unit 1312 mechanically expands the pipes inserted into the fins, ensuring close contact between the pipes and the fins and improving heat exchange efficiency. The tube opening inspection unit 1314 inspects the quality of the expanded pipe openings. The drying unit 1315 dries the semi-finished heat exchanger. The elbow installation unit 1316 installs connecting elbows for the heat exchanger. The nitrogen filling unit 1318 fills the heat exchanger with nitrogen to prepare for welding and provide initial airtightness. The elbow welding unit 1317 welds the installed elbows. The weld appearance inspection unit 1318 inspects the appearance quality of the welds. The vacuum He inspection unit 1319 places the heat exchanger in a vacuum environment and performs precise leak inspections using helium mass spectrometry to ensure the airtightness of the product.

[0017] Unit shelves 1321 are located near each production unit to temporarily store materials or semi-finished products awaiting processing. An input device 1016 automatically supplies materials from the shelves to the corresponding production unit. Material detection devices 1015 are installed at key work locations in the production units to monitor the arrival status and quantity of materials and ensure production continuity. Starting with the pipe expansion unit 1312, several subsequent key units (such as the pipe mouth inspection unit 1314, drying unit 1315, elbow installation unit 1316, elbow welding unit 1317, weld appearance inspection unit 1318, and vacuum helium inspection unit 1319) are equipped with RFID information acquisition modules 1019. These modules read and write electronic tag information on products during production, enabling full-scale tracking of the production process. In some embodiments, as shown in Figure 2, the factory is an unmanned (black light) factory, with no permanently lit lighting equipment. Instead, each production unit is equipped with lighting equipment 1320, which is always kept off. The lighting equipment 1320 is installed in each production unit, and when the equipment malfunctions or has an abnormality, the lighting equipment 1320 lights up to illuminate the corresponding production unit, facilitating operation and maintenance for technicians, saving a large amount of energy and significantly reducing the power consumption of the production system.

[0018] As shown in Figure 2, the quality control node is used for the rejected product processing process. For example, if a product is found to be unacceptable in processes such as the pipe nozzle inspection unit 1314, the weld visual inspection unit 1318, or the vacuum helium inspection unit 1319, the product is sorted and sent for repair or disposal, and is not passed on to the next process. If the product is unacceptable, it is output via the rejected product conveying line and notified to the control system, which then controls the conveying system to transport all materials from the upstream process of the inspection unit in the packaging system. If the inspection unit detects a reject, the production process is adjusted accordingly. In Figure 2, the heat exchanger sub-control system 1014 performs centralized control and scheduling, coordinating the operating status of each unit, material transport, and quality data collection and processing.

[0019] In some embodiments, as shown in FIG. 3 , indoor unit production system 102 is used to produce indoor units using indoor heat exchangers and indoor unit materials. Indoor unit production system 102 includes a plurality of indoor unit production units. In some embodiments, as shown in FIG. 4 , air conditioner production, operation, and maintenance system 100 further includes a bending unit 107, which is configured to bend an unbent outdoor heat exchanger into an outdoor heat exchanger. Outdoor unit production system 103 is configured to produce outdoor units using the outdoor heat exchanger and outdoor unit materials. Outdoor unit production system 103 includes a plurality of outdoor unit production units. Bending unit 107 is located in outdoor unit production system 103 and controlled by outdoor unit production system 103. In some embodiments, bending unit 107 may be located in indoor unit production system 102 and controlled by indoor unit production system 102. In some embodiments, material storage system 105 is configured to store heat exchanger materials, indoor unit materials, and outdoor unit materials. The transport system 108 is configured to transport heat exchanger materials to the general-purpose heat exchanger production system 101, transport indoor unit materials to the indoor unit production system 102, and transport outdoor unit materials to the outdoor unit production system 103.

[0020] In some embodiments, as shown in FIG. 3 , the production line starts with the indoor heat exchanger input unit 2019. Passed indoor heat exchangers manufactured and inspected by the general-purpose heat exchanger production system 101 are transported to the indoor unit production system 102. The pallet information creation unit 1027 creates a unique electronic identifier (e.g., an RFID tag) on ​​the pallet carrying the indoor unit components before formal assembly. This pallet moves throughout the production line with the product, and its identity information is linked to the product information, providing the key to tracking a single product throughout its entire process. The pallet information creation unit is used to create pallet information on the pallet, formed from each pallet's unique identifier. When the finished product is input, the control system reads the end plate information of the input heat exchanger and commands it to associate and bind its source information to the unique information of the current pallet. From this point on, this pallet becomes a mobile carrier that aggregates all information related to that particular product in all subsequent assembly, welding, and inspection processes.

[0021] As shown in Figure 3, the main assembly process units are controlled in the following order: The indoor heat exchanger mounting unit 1022 securely mounts the heat exchanger to a pallet or base. The electronic expansion valve mounting unit 1021 mounts an electronic expansion valve for precise refrigerant flow control. The internal unit piping welding unit 1023 automatically welds the electronic expansion valve and other internal piping to the heat exchanger. The weld visual inspection unit 2010 uses machine vision and other technologies to inspect the quality of the welds online. Products that fail inspection are diverted from this work location and do not proceed to the next process. If a product fails, it is output via a rejected product conveying line and notified to the control system, which then controls the conveying system to transport all materials upstream of the inspection unit in the packaging system. If the inspection unit detects a failure, the production process is adjusted accordingly. The side panel mounting unit 2011 mounts the side structural panels of the indoor unit. The partition panel mounting unit 2012 mounts the partition panels for the internal functional areas. The motor and its component mounting unit 2013 mounts the motor that drives the fan and related components. The pump mounting unit 2014 mounts the pump for discharging condensed water. The water receiving panel mounting unit 2015 mounts the water receiving panel for collecting and guiding condensed water. The electrical box mounting unit 2016 mounts the electrical control box including the main control board and electronic components. The wiring mounting unit 2017 performs electrical wiring between the motor, sensors, main control board, etc. The front and rear cover plate mounting unit 2018 mounts the outer shell of the indoor unit and completes the encapsulation of the finished unit.

[0022] After the assembly of the finished unit is complete, the detection unit 2029 performs comprehensive functional and performance inspection. The results of this inspection also determine whether the product passes. Rejected products are disposed of, while accepted products proceed to the next process. If a product fails, it is output via the rejected product conveyor line and notified to the control system. The control system then controls the conveyor system to transport all materials from the upstream process of the detection unit to the packaging system. If the detection unit detects a reject, it adjusts the production process accordingly. Once a finished indoor unit passes all assembly and inspection and passes, it is transported from the end of the production line by the conveyor system 108 and sent to the packaging system or the finished product warehouse. As shown in Figure 3, each mounting and detection unit is equipped with an RFID information acquisition module 1026. As the product passes, the system automatically reads and writes tags on the pallet, recording information such as the completion status of the current process, the material lot used, and process parameters, and uploading the data to the indoor unit sub-control system 1024. A material supply system is located near each mounting unit, including a unit shelf 1029 for storing parts, a dosing device 1028 that automatically supplies materials to the assembly position, and a material detection device 1025 that monitors remaining material levels in real time, jointly ensuring automation and continuity of production. The indoor unit sub-control system 1024 manages and coordinates the interaction of all hardware equipment, material flow, and information throughout the indoor unit production line, ensuring the efficiency and accuracy of the production process. In some embodiments, as shown in FIG. 3 , the factory is an unmanned (black light) factory, and no lighting equipment is installed that is always on. Instead, each production unit is equipped with lighting equipment 2020 that is always off. The lighting equipment 2020 is installed in each production unit, and when an equipment malfunctions or an abnormality occurs, the lighting equipment 2020 turns on, illuminating the corresponding production unit and facilitating operation and maintenance for technicians. This saves a lot of energy and significantly reduces the power consumption of the production system.

[0023] In some embodiments, as shown in Figure 4, the start of the production line is the outdoor heat exchanger input unit 3010. Inspected and qualified outdoor heat exchangers transported from the general-purpose heat exchanger production system 101 enter the outdoor unit production system 103. The pallet information creation unit 1037, like the pallet information creation unit 1027 of the indoor unit production system 102, creates unique RFID electronic tags on pallets carrying outdoor unit components, linking the products to the pallets and laying the foundation for information tracking for all subsequent processes.

[0024] As shown in Figure 4, the main assembly and inspection process units are controlled in the following order: The outdoor heat exchanger mounting unit 3012 mounts and fixes the heat exchanger to the base. The compressor mounting unit 3011 mounts the air conditioning system compressor. The outdoor unit pipe welding and valve mounting unit 3013 connects and automatically welds the pipes between the compressor, heat exchanger, and various valves (such as shut-off valves). The weld visual inspection unit 3014 performs online visual inspection of the pipe welding quality, and any rejected products are identified and diverted. If a product fails, it is output via a rejected product conveying line and notified to the control system, which then controls the conveying system to transport all materials upstream of the inspection unit within the packaging system. If a reject is detected by the inspection unit, the production process is adjusted accordingly. The side plate mounting unit 3015 mounts the side sheet metal parts of the outdoor unit. The partition plate mounting unit 3016 mounts internal partition plates to separate different functional areas (such as the compressor room and fan room). The motor and its component mounting unit 3017 mounts the fan motor and its supporting components. The fan mounting unit 3018 mounts the fan blades to the motor. The airtightness testing unit 3019 pressurizes the entire refrigerant piping system to detect leaks. This is a critical quality control point, and any rejected products are rejected. The vacuum and refrigerant charging unit 3020 vacuums the piping system that has passed the airtightness test and accurately charges it with refrigerant according to the standard amount. The front cover plate mounting unit 3021 mounts the front outer shell panel. The electrical box mounting unit 3022 mounts the control box, which houses electrical components such as control circuits and terminal blocks. The wiring mounting unit 3023 makes all electrical connections between the compressor, motor, sensors, and the electrical box. The grill, support plate, and top cover plate mounting unit 3024 mounts the fan grill, upper support structure, and top cover plate, completing the physical assembly of the finished machine.

[0025] The four-item commercial safety and halogen inspection unit 3025 performs comprehensive pre-shipment required inspections on finished units, including electrical safety performance tests (safety standards), commercial performance index tests, and halogen leak detection. The shut-off valve fixing unit 3026 finally fixes the external shut-off valve. The inspection cover mounting unit 3027 installs an inspection cover plate to facilitate future operation and maintenance. The insulation and rear cover plate mounting unit 3028 wraps insulation around specific pipes and installs a rear cover plate. The appearance inspection unit 3029 inspects the final appearance of the finished outdoor unit to ensure there are no scratches, dents, or other defects. Only qualified products that have passed all assembly and inspection processes are transported from the end of the production line to the packaging area by the conveyor system 108.

[0026] Each unit is equipped with an information acquisition module (RFID) 1036, which reads and writes product information in real time, records assembly data and inspection results, and forms a complete product electronic file. Each mounting unit is equipped with a unit shelf 1038, an input device 1039, and a material inspection device 1035, enabling unmanned and precise component supply. Figure 4 clearly shows multiple "fail" diversion paths, including welding visual inspection, airtightness inspection, final safety inspection, and visual inspection, forming a strict online quality control system. Rejected products are output via a reject conveyor line and notified to the control system, which then controls the conveyor system to transport all materials upstream of the inspection unit through the packaging system. If a reject is detected by the inspection unit, the production process is adjusted accordingly. The outdoor unit sub-control system 1034 is the control part of the outdoor unit production system 103. It unifies the scheduling of all automated equipment, processes large amounts of production data, and executes complex quality control logic. In some embodiments, as shown in Figure 4, the factory is an unmanned (black light) factory, and no lighting equipment is installed that is always on. Instead, each production unit is equipped with lighting equipment 3030 that is always off. Lighting equipment 3030 is installed in each production unit, and in the event of an equipment malfunction or abnormality, lighting equipment 3030 turns on to illuminate the corresponding production unit, facilitating operation and maintenance for technicians, saving a large amount of energy and significantly reducing the power consumption of the production system.

[0027] 5 , the start of the production line is the finished machine input unit 4010, the starting point of the production process in the packaging system 104. Accepted finished products that come off the line from the indoor unit production system 102 or the outdoor unit production system 103 are transported to the finished machine input unit 4010 in the packaging system 104 by the transport equipment of the transport system 108. The pallet information creation unit 4011 creates a unique electronic identity identifier (such as an RFID tag) on ​​the pallet or base used to mount and transport the packaged finished products. At the same time, the packaging system 104 associates the information of the finished machine to be input (by scanning the linked ID during the assembly process) with this new pallet ID, extending the product's production history data chain to the packaging and storage stages.

[0028] As shown in Figure 5, the automated packaging process is primarily controlled in the following order: The finished machine bagging unit 4012 automatically covers the finished machine with a dust-proof, moisture-proof protective plastic bag. The finished machine boxing unit 4013 places the bagged finished machine into a pre-formed cardboard box. The label printing and application unit 4014 automatically prints labels containing information such as the model, serial number, specifications, and barcode based on the scanned product information, and then uses a device such as a robotic arm to accurately apply the labels to the designated location on the box. The packing strapping unit 4015 sends the packing box to the automatic packing machine, where it is reinforced with packing straps to ensure stability during transportation. In the label printing and application unit, the packaging sub-control system receives pallet information related to the finished machine currently awaiting packaging through the control system. Based on the pallet information, the control system automatically tracks the source end plate information associated with the initial assembly stage and retrieves and integrates all material information, supplier information, production process information for each process, and quality inspection results related to the product. This integrated and complete information is sent to the production information creation unit (this unit), which creates a production label containing a unique product serial number, QR code, etc., and automatically affixes it to a designated location on the packaging box, thereby completing the entire information tracking chain starting from the core parts and finally solidifying it on the packaging, completing the final output of information tracking.

[0029] After all packaging processes are completed, the packaging box visual inspection unit 4016 uses technology such as machine vision to perform an online final visual inspection of the packaging box, checking for defects such as damage, tilted labels, and loose packaging straps. This is an important quality control node. Products that pass the inspection proceed to the next process. For products that fail the inspection, the packaging system 104 issues a command to sort them from the main line for manual processing or rework. If a product fails the inspection, it is output via the reject conveyor line and notified to the control system, which then controls the conveyor system to transport all materials upstream of the inspection unit within the packaging system. If the inspection unit detects a failure, the production process is adjusted accordingly. Finished products that pass all packaging processes and visual inspection are automatically removed from the end of the packaging line by the conveyor system 108 and, according to the command of the control system 106, transported to a designated location in the finished product warehouse or to a direct shipping area.

[0030] Each unit (bagging, boxing, pasting, packaging) is equipped with an information acquisition module (RFID) 1046 to track the progress of products along the packaging line in real time and record the completion status of each process, ensuring complete data traceability of the packaging process. Each unit is also equipped with a unit shelf 1044, an input device 1049, and a material detection device 1045 to automatically supply consumables such as packaging bags, cardboard boxes, label paper, and packaging strips. The remaining consumables are monitored in real time, triggering automatic warnings or replenishment when necessary, ensuring continuous and stable operation of the packaging line. The automation equipment, information acquisition module, material supply unit, and transport scheduling of the entire packaging system 104 are all centrally controlled and coordinated by the packaging sub-control system 1041, which exchanges data with the control system 106. In some embodiments, as shown in FIG. 5, the factory is an unmanned (black light) factory, with no lighting equipment always on. Instead, each production unit is equipped with lighting equipment 4020, which is always off. The lighting equipment 4020 is installed in each production unit, and when an equipment malfunctions or an abnormality occurs, the lighting equipment 4020 lights up to illuminate the corresponding production unit, facilitating operation and maintenance for technicians, saving a large amount of energy and significantly reducing the power consumption of the production system.

[0031] 6 , the control system 106 communicates with the general-purpose heat exchanger production system 101, the indoor unit production system 102, the outdoor unit production system 103, the material storage system 105, and the conveying system 108. The control system 106 is configured to unify, coordinate, and control the operating states of all systems and obtain relevant information for all systems. In some embodiments, the control system 106 is configured to control the conveying system 108 to convey materials, control the indoor heat exchanger fin production unit 1011 and the general-purpose heat exchanger production unit 1013 to produce indoor heat exchangers, control the indoor unit production system 102 to produce indoor units using the indoor heat exchangers and indoor unit materials, control the outdoor heat exchanger fin production unit 1012, the general-purpose heat exchanger production unit 1013, and the bending unit 107 to produce outdoor heat exchangers, and control the outdoor unit production system 103 to produce outdoor units using the outdoor heat exchangers and outdoor unit materials. By producing indoor heat exchangers and outdoor heat exchangers through the general-purpose heat exchanger production system 101, and controlling the general-purpose heat exchanger production system 101 based on the production needs of indoor units and outdoor units to produce outdoor heat exchangers or indoor heat exchangers, the spatial layout and layout costs of the entire production system can be effectively reduced.

[0032] In some embodiments, as shown in Figure 6, the air conditioner production, operation, and maintenance system 100 can be understood as having three main layers, from left to right and top to bottom: the decision-making management layer, the central control layer, and the equipment execution layer. The display panel 110 is the human-machine interface and advanced management interface for the entire production system. It not only visualizes the production status, but also serves as the input for production decision-making and a collection of management functions. Its core functional modules are as follows: Demand determination and production process establishment: Receives order information (or big data-based forecasts) and automatically analyzes it to generate production plans and process processes. Material transportation and replenishment of rejected materials: Issues material transportation orders based on the production plan and real-time inventory. If rejected products are detected, automatic replenishment or rework processes can be initiated. Production monitoring: Displays key performance indicators, such as the operating status of each production line, equipment parameters, work-in-process quantities, and production takt time, in real time. Abnormality warning: Through real-time analysis of equipment status data, potential equipment failures or process abnormalities can be predicted and warned in advance, enabling predictive maintenance. Energy-saving control: According to the production load, the energy consumption of non-critical equipment such as lighting and standby equipment can be adjusted to achieve green manufacturing. Quality tracking: By providing an inquiry interface and entering information such as the product serial number, the entire lifecycle production data of the relevant product can be tracked from the receipt of materials to the delivery of the finished product.

[0033] The control system 106 is the "brain" of the entire system, playing a central role in connecting the upper and lower levels. It receives high-level commands from the display panel 110, breaks them down into specific executable task commands, and issues them to each equipment execution level subsystem. At the same time, it collects, processes, and analyzes status information, production data, and detection results uploaded from all sub-control systems in real time, and then feeds them back to the display panel 110 for display and decision-making support.

[0034] The equipment execution layer is composed of a series of independent, distributed sub-control systems, each responsible for managing a specific production area. This distributed control architecture improves the robustness and response speed of the system. The material management system 1051 and finished machine management system 1071 are responsible for automated warehouse management of raw materials, semi-finished products, and finished products. They control the operation of the material storage system 105 and the finished machine storage system 170, respectively, enabling automatic material inventory and accurate inventory and retrieval. The heat exchanger sub-control system 1014 is responsible for the automated production of heat exchangers and controls the operation of the general-purpose heat exchanger production system. The indoor unit sub-control system 1024 is responsible for the automated assembly and inspection of indoor units and controls the operation of the indoor unit production system 102. The outdoor unit sub-control system 1034 is responsible for the automated assembly and inspection of outdoor units and controls the operation of the outdoor unit production system 103. The packaging sub-control system 1041 is responsible for the automated packaging of finished products and controls the operation of the packaging system 104. The transport sub-control system 1084 is responsible for scheduling logistics equipment such as AGVs and conveyors, realizing the automatic flow of materials and products between each subsystem, and controlling the operation of the transport system 108.

[0035] In some embodiments, the heat exchanger general-purpose production system 101 includes a heat exchanger sub-control system 1014, the indoor unit production system 102 includes an indoor unit sub-control system 1024, and the outdoor unit production system 103 includes an outdoor unit sub-control system 1034. The heat exchanger sub-control system 1014, the indoor unit sub-control system 1024, and the outdoor unit sub-control system 1034 are each configured to communicate with the control system 106 for data transmission and exchange. The heat exchanger sub-control system 1014, the indoor unit sub-control system 1024, and the outdoor unit sub-control system 1034 are each configured to receive detection information from their respective production systems and control the operating status of their respective associated production systems. Each sub-control system processes data and then uploads it to the control system, thereby reducing the amount of information transmission and the calculation load on the control system.

[0036] 6, the transport system 108 includes a transport sub-control system 1084, which is in communication with the control system 106. In some embodiments, the transport system 108 does not include a control system and is managed and controlled by the material management system 1051. The finished machine storage system 170 is managed and controlled by the finished machine management system 1071.

[0037] 7, in combination with FIG. 5, the transport system 108 includes an overhead crane system, and the overhead crane system includes rails 80 and an overhead crane 81. A portion of the rail is located above the heat exchanger general-purpose production system 101, the indoor unit production system 102, the outdoor unit production system 103, and the material storage system 105, facilitating material supply by the overhead crane 81. The overhead crane 81 is located on the rails 80, and the overhead crane includes a gripping device 811 and a position sensing device 812. The gripping device 811 is configured to grip the material, and the position sensing device 812 is configured to sense whether the overhead crane has reached the production unit or the material storage system.

[0038] In some embodiments, the overhead crane system includes a material box 813, which is used to store materials. The gripping device 811 is used to grip the material box 813. By installing the material box 813, the gripping device 811 only needs to grip the material box 813, avoiding the complexity of the design of the gripping device 811 due to gripping different materials. The overhead crane system includes a traveling mechanism 82, which is used to run the overhead crane 81 on the rails 80. In some embodiments, the gripping device 811 is connected to the overhead crane 81 via a lifting mechanism 814. The lifting mechanism 814 includes a lifting motor and a lifting rope. The gripping device 811 includes a base 8111, a screw shaft 8112, a screw shaft drive mechanism 8113, and a jig 8114. The base 8111 is connected to the lifting mechanism 814. Two screw shafts 8112, two screw shaft driving mechanisms 8113, and two jigs 8114 are installed, and each screw shaft driving mechanism 8113 drives the rotation of one screw shaft 8112 and moves one jig 8114. The screw shafts 8112 are rotatably attached to the base 8111. The screw shaft driving mechanism 8113 is used to drive the screw shafts 8112 to rotate, and the jig 8114 is screwed onto the screw shafts 8112. The two screw shaft driving mechanisms 8113 drive the rotation of the two screw shafts 8112, respectively, and control the opening and closing of the two jigs 8114.

[0039] In some embodiments, the screw shaft rotates to increase the distance between the two jigs, opening the jigs, and the screw shaft rotates in the opposite direction to decrease the distance between the two jigs, closing the jigs and clamping the material box. In some embodiments, the gripping device includes a jig position limiting member 8115, which is used to limit the position of the jigs 8114. There are two jig position limiting members 8115 corresponding to each jig 8114, one jig position limiting member 8115 corresponding to the jig open position and one jig position limiting member 8115 corresponding to the jig closed position.

[0040] In some embodiments, the overhead crane 81 includes two arms 815 located on either side of the gripping device, and a position sensing device 812 is installed at the bottom end of the arms 815 to facilitate position sensing by the position sensing device 812. In some embodiments, the position sensing device 812 is a laser scanning device. In some embodiments, the rail is a closed loop rail to achieve circulating supply. In some embodiments, the indoor unit production system and the outdoor unit production system are arranged in parallel between the heat exchanger general production system and the material storage system.

[0041] In some embodiments, as shown in FIG. 1, a general-purpose heat exchanger production system 101, a parallel indoor unit production system 102, an outdoor unit production system 103, and a material storage system 105 are arranged in this order along the production line.

[0042] The indoor unit production system 102 and the outdoor unit production system 103 are installed in parallel downstream of the heat exchanger general-purpose production system 101, making it easy to transport heat exchangers to the indoor unit production system 102 and the outdoor unit production system 103, respectively.

[0043] Rail 80 includes overhead crane standby rail section 806, material rail section 801, heat exchanger rail section 802, indoor unit rail section 803, outdoor unit rail section 804, packaging rail section 807, first rail section 8051, second rail section 8052, third rail section 8053, fourth rail section 8054, fifth rail section 8055, sixth rail section 8056, and seventh rail section 8057. In some embodiments, material rail section 801 includes five sub-rail sections, namely indoor unit heat exchanger material rail section (1), outdoor unit heat exchanger material rail section (2), indoor unit material rail section (3), outdoor unit material rail section (4), and packaging material rail section (5), and these five sub-rail sections are spaced apart to prevent collisions between them, operate in accordance with their respective transportation target systems, and transport materials sequentially according to the rail sequence.

[0044] The material rail section 801 is located above the material storage system 105, the heat exchanger rail section 802 is located above the heat exchanger general-purpose production system 101, the indoor unit rail section 803 is located above the indoor unit production system 102, and the outdoor unit rail section 804 is located above the outdoor unit production system 103.

[0045] The first rail section 8051 connects the material rail section 801 and the heat exchanger rail section 802, and the first rail section 8051 is located between the indoor unit rail section 803 and the outdoor unit rail section 804. The second rail section 8052 connects the heat exchanger rail section 802 and the indoor unit rail section 803. The third rail section 8053 connects the first rail section 8051 and the indoor unit rail section 803. The fourth rail section 8054 connects the indoor unit rail section 803 and the material rail section 801. The fifth rail section 8055 connects the first rail section 8051 and the outdoor unit rail section 804. The sixth rail section 8056 connects the outdoor unit rail section 804 and the material rail section 801.

[0046] The overhead crane is configured as follows: it travels up to the material rail section, picks up a material box containing heat exchanger materials, travels via the first rail section to the heat exchanger rail section and releases the heat exchanger materials to the general-purpose heat exchanger production system, then travels via the second rail section and indoor unit rail section to the fourth rail section; it travels up to the material rail section, picks up a material box containing indoor unit materials, travels via the first and third rail sections to the indoor unit rail section and releases the indoor unit materials to the indoor unit production system, then reaches the fourth rail section; it travels up to the material rail section, picks up a material box containing outdoor unit materials, travels via the first and fifth rail sections to the outdoor unit rail section and releases the outdoor unit materials to the outdoor unit production system, then reaches the sixth rail section.

[0047] In some embodiments, rail 80 includes overhead crane waiting rail section 806, which is located between fourth rail section 8054 and material rail section 801, and sixth rail section 8056 and material rail section 801. Fourth rail section 8054 and sixth rail section 8056 may or may not be connected. Overhead crane 81 is configured to reach overhead crane waiting rail section 806 after completing material transport and wait at overhead crane waiting rail section 806.

[0048] In some embodiments, as shown in FIG. 6 , the material storage system 105 includes a material management system 1051 configured to manage material information, and the material management system 1051 communicates with the control system 106 and uploads the material information to the control system.

[0049] In some embodiments, as shown in FIG. 1 , the air conditioner production operation and maintenance system 100 further includes a packaging system 104, which is used to receive and package the indoor and outdoor units. An overhead crane system is configured to transport packaging material to the packaging system. The packaging material is divided into indoor unit packaging material and outdoor unit packaging material, and both are transported to the packaging system simultaneously or separately. A ground transfer device is used to transport the indoor units and outdoor units to the packaging system.

[0050] The control system determines whether it is an indoor unit or an outdoor unit that is about to arrive at the packaging system based on the production status of the outdoor unit production system and the indoor unit production system, and sends the relevant information to the packaging system. If it is an indoor unit that is arriving at the packaging system, the packaging system inputs packaging materials for the indoor unit and packs the indoor unit, and if it is an outdoor unit that is arriving at the packaging system, the packaging system inputs packaging materials for the outdoor unit and packs the outdoor unit.

[0051] In some embodiments, the packaging materials are stored in a material storage system.

[0052] In some embodiments, the packaging system is located below the sixth rail section of the conveying system, with a seventh rail section 8057 connecting the material rail section and the sixth rail section.

[0053] The overhead crane is configured to travel up to the material rail section, grab a material box containing packaging material, release the packaging material to the packaging system 104 when it reaches the packaging rail section 807 via the seventh rail section 8057, and then reach the overhead crane waiting rail section 806 via the sixth rail section 8056.

[0054] In some embodiments, the packaging system is located downstream of the outdoor unit production system and the material storage system is located downstream of the indoor unit production system.

[0055] The seventh rail section of the conveyor system is located between the outdoor unit production system and the packaging system.

[0056] This layout method makes the structural layout of the entire production system more rational, allows for smoother material transport, and improves production efficiency.

[0057] In some embodiments, the material storage system includes a material storage shelf and a material transport device.

[0058] The material storage shelf is used to store materials.

[0059] The material transport device receives the transport material information, and when a material on the material storage shelf is identified as the transport material, transports the transport material to the transport system.

[0060] Material transport information is generated by the control system and transmitted to the material transport device.

[0061] In some embodiments, the control system is in communication with a material management system, the transport material information is transmitted by the control system to the material management system, and the material management system transmits the transport material information to the material transport device.

[0062] In some embodiments, the material transport device determines whether transport of the transported material is complete, and after transport of the transported material is complete, the material transport device sends information to the material management system, the material management system changes the material information, the material management system controls the transport system to perform the transport, and sends the information to the control system.

[0063] In some embodiments, the material storage system includes a material inventory information acquisition module, which is used to acquire and transmit material inventory information to the material management system.

[0064] In some embodiments, the material inventory information acquisition module is an RFID scanning device.

[0065] When materials are received, the time of receiving the materials, quantity, specifications, model, supplier information, storage location, etc. are first recorded as an electronic tag, which is then attached to the corresponding shelf. After the materials are placed on the corresponding shelf, the material storage system records the relevant information and transmits it to the control system.

[0066] In some embodiments, the material storage shelves include a heat exchanger material storage shelf, an indoor unit material storage shelf, and an outdoor unit material storage shelf, and correspondingly, the material rail sections of the conveying system include a heat exchanger material rail section located above the heat exchanger material storage shelf, an outdoor unit material rail section located above the outdoor unit material storage shelf, and an indoor unit material rail section located above the indoor unit material storage shelf.

[0067] In some embodiments, the heat exchanger material storage shelf is divided into an indoor heat exchanger material storage shelf and an outdoor heat exchanger material storage shelf to facilitate material transport.

[0068] In some embodiments, the material storage shelves employ a multi-tiered shelf structure, with each shelf corresponding to a specific material, a specific material transport device, and a specific overhead crane, ensuring rational storage and convenient access to materials.

[0069] In some embodiments of FIG. 1, the fully automated intelligent manufacturing system further includes a finished machine storage system, which is used to store the finished machines that have been packaged in the packaging system.

[0070] In some embodiments, the finished machine storage system and the material storage system are two separate systems.

[0071] The finished aircraft storage system includes a finished aircraft inventory information acquisition unit and a finished aircraft management system.

[0072] The completed machine inventory information acquisition unit is used to acquire completed machine inventory information and transmit it to the completed machine management system.

[0073] The completed aircraft management system is used to manage completed aircraft information, and the completed aircraft management system communicates with the control system and uploads the completed aircraft information to the control system.

[0074] In some embodiments, the ground transfer device is used to transport the completed aircraft that has been packaged in the packaging system to the completed aircraft storage system.

[0075] In some embodiments, the ground transfer device is an Automated Guided Vehicle (AGV).

[0076] In some embodiments, the finished machine storage system includes a multi-tiered shelf structure. When the finished machine is packed and stored, the finished machine management system first issues a corresponding transport shelf command. After the finished machine storage AGV receives the command, it transports the packaged finished machine to a specific shelf, and the storage transport robot transports the finished machine to the specific shelf. The AGV carrying the finished machine records information through a storage information acquisition unit—an RFID tag scanning device—located on the shelf, and the information is simultaneously transmitted to the finished machine storage system. The information includes the storage time, quantity, specifications, model, storage location, etc.

[0077] In some embodiments, the packaged finished machine is also stored in a material storage system, and the material management system manages the finished machine information and uploads the finished machine information to the control system.

[0078] In some embodiments, a material storage system for storing finished machines forms a warehouse.

[0079] The layout of the warehouse, general-purpose heat exchanger production system, indoor unit production system, outdoor unit production system, and packaging system forms one final assembly production line, with an overhead crane transport system installed around the production line, ground transfer equipment used between systems, and roller transport lines used within the system.

[0080] The ground transfer device is used to receive control information from the control system and transfer assembled parts between units according to the control information.

[0081] The ground transfer device is used to transport indoor heat exchangers to the indoor unit production system, transport outdoor heat exchangers to the outdoor unit production system, transport the outdoor units and indoor units to the packaging system, and transport finished units that have been packaged in the packaging system to the finished unit storage system.

[0082] In some embodiments, the ground transfer device is universal and transfers between any two systems can be performed by the ground transfer device.

[0083] In some embodiments, the ground transfer devices are only responsible for transfers between two systems and include a first ground transfer device between the heat exchanger general-purpose production system and the indoor unit production system, a second ground transfer device between the heat exchanger general-purpose production system and the outdoor unit production system, a third ground transfer device between the indoor unit production system and the packaging system, a fourth ground transfer device between the outdoor unit production system and the packaging system, and a fifth ground transfer device between the packaging system and the finished unit storage system.

[0084] The control system monitors the detection information of the detection unit at the end of the production system through each sub-control system, outputs control information to the ground transfer device based on the detection information, and when the detection unit at the end of the production system detects a pass, controls the ground transfer device through the sub-control system corresponding to the ground transfer device to transfer the assembled parts between units. Roller conveyor lines are used to connect the production units in each production system.

[0085] In some embodiments of Figures 2 to 5, the heat exchanger general-purpose production system, the indoor unit production system, the outdoor unit production system, and the packaging system all include multiple unit shelves, which are located near the production units and are used to receive materials transported from the transport system.

[0086] The unit shelf includes an identifier or a signal generator that is detected by a position sensor of the transport system. When the position sensor of the overhead crane detects the signal from the identifier or signal generator and the overhead crane reaches the corresponding unit shelf, the overhead crane stops and transfers the material in the overhead crane material box to the unit shelf.

[0087] The production unit includes an input device and a material detection device.

[0088] The input device is used to input materials from the unit shelf into the production unit.

[0089] The material detection device is used to detect the quantity of material on the unit shelf, and the control system is configured to control the conveying system to convey the material when the quantity of material falls below a threshold value.

[0090] The unit shelf includes a material box storage area and a temporary material storage area, and the material box transported from the overhead crane can be placed in the material box storage area, and the material in the material box can be fed into the temporary material storage area by the feeding device.

[0091] In some embodiments, material bins are placed in a material bin storage area, and if a material detection device detects a shortage of material or a rejection occurs at the detection unit, an overhead crane system grasps the material bin and refills the material storage system. A rejection is output via a reject conveyance line and notified to a control system, which then controls a conveyance system to convey all material upstream of the detection unit in the packaging system. If a rejection is detected at the detection unit, the production process is adjusted accordingly.

[0092] In some embodiments of Figures 2 to 5, the general-purpose heat exchanger production system, the indoor unit production system, the outdoor unit production system, and the packaging system all include multiple detection units, and the detection units are used to detect whether the product is pass or fail. If the detection result of the detection unit is fail, it outputs it through a reject product conveying line and sends the fail information to the sub-control system, and the sub-control system sends the information to the control system.

[0093] In some embodiments, after the detection unit acquires the detection data, it transmits the detection data to the sub-control system in which the detection unit is located, and the sub-control system determines whether the product passes or fails based on the detection data. If the product passes, it transports it to the next process, and if the product fails, it outputs it via a reject product transport line.

[0094] The control system controls the transport system to transport the material ahead of the detection unit for reproduction.

[0095] In some embodiments of FIG. 2, the heat exchanger generic production system includes an end plate information creation unit.

[0096] The end plate information creating unit is used to form a unique identifier for each end plate as end plate information and create it on the end plate.

[0097] The production unit of the heat exchanger general-purpose production system includes an information acquisition module, which is used to acquire end plate information arriving at the production unit, and transmits the end plate information to the control system through the sub-control system, facilitating monitoring by the control system.

[0098] The information acquisition module uploads the acquired end plate information to the control system, and the control system associates the heat exchanger material information with the end plate information.

[0099] In some embodiments, the control system is configured to send material information of the transported heat exchanger and the corresponding indoor unit or outdoor unit to an end plate information creation unit, which is used to form a unique identifier of the end plate and its associated material information as end plate information.

[0100] If the end plate is an end plate of an indoor unit, the end plate information includes a unique identifier of the end plate and information on all materials that make up the indoor unit, and if the end plate is an end plate of an outdoor unit, the end plate information includes a unique identifier of the end plate and information on all materials that make up the outdoor unit. Therefore, if a malfunction occurs during use of the air conditioner, all material information can be obtained through the end plate information, thereby realizing quality tracking.

[0101] In some embodiments of FIGS. 3 and 4, the indoor unit production system and the outdoor unit production system include a pallet information creation unit.

[0102] The pallet information creation unit is used to create pallet information on the pallets, which is formed from the unique identifier of each pallet.

[0103] The production units of the indoor unit production system and the outdoor unit production system are installed with information acquisition modules, which are used to acquire information on pallets that have arrived at the production units, and transmit the pallet information to the control system through the sub-control system, facilitating monitoring by the control system.

[0104] The information acquisition module uploads the acquired pallet information to the control system through the sub-control system, and the control system associates the pallet information with the indoor unit material or the outdoor unit material, and the control system is configured to monitor the pallet information of the production unit.

[0105] The packaging system includes a packaging sub-control system, which communicates and exchanges data with the control system. In some embodiments of Figure 5, the packaging system includes a packaging pallet information creation unit, which is used to create a unique identifier for each pallet on the pallet.

[0106] The production unit of the packaging system is equipped with an information acquisition module (RFID), which is used to acquire the information of the packaging pallets that arrive at the production unit, and transmits the packaging pallet information to the control system through the sub-control system, making it easier for the control system to monitor.

[0107] In some embodiments, the control system transmits whether the unit being delivered is an indoor unit or an outdoor unit, and transmits an identification of the indoor unit or the outdoor unit to a pallet information creation unit, which creates an identification of the indoor unit or the outdoor unit and a unique identifier for the pallet on the pallet. If the unit being delivered is an indoor unit, the packaging system controls the loading device to load indoor unit packaging material, and if the unit being delivered is an outdoor unit, the packaging system controls the loading device to load outdoor unit packaging material.

[0108] The information acquisition module can also acquire the mark of the indoor unit or the outdoor unit, and if the mark is the indoor unit, insert the indoor unit packaging material, and if the mark is the outdoor unit, insert the outdoor unit packaging material.

[0109] The packaging system includes a production information creation unit, which is used to create a production label on the package.

[0110] The production information creation unit receives production information formed from material information, supplier information, production product information, production process information, etc. related to end plate information sent from the control system through the packaging sub-control system, and creates the production information as a production label and places it on the packaging.

[0111] The material information includes the material name and material lot.

[0112] Produced product information includes: Product number: Uniquely identifies the product and makes it easy to track it through the production process. Product model and specifications: Identify the specific model and specifications of the product. Production Date: Record the date the product was manufactured. Production lot number: Linked to the production management system and used to track the production process.

[0113] Production process information includes: Process route: Record the processing process flow of the product. Location information: Records the location of a material or product on a production line. Processing parameters: the operating temperature, time and pressure of the production equipment at the relevant working position. Process Information: Records the process that the product has currently completed. Quality inspection results: Record the results of each product inspection stage.

[0114] In some embodiments, the information acquisition module is an RFID scanning device that communicates with its control system to track and upload code data during the assembly process in real time, exchange information, and ensure transparency and traceability of the production process.

[0115] By linking the inventory information acquisition unit, information acquisition module, end plate information creation unit, pallet information creation unit, and packaging information creation unit, production can be monitored in real time, and information exchange, tracking, and a closed loop can be achieved from material inventory to finished machine inventory.

[0116] In some embodiments, the production unit includes a production unit status detection module.

[0117] The production unit status detection module is used to detect the operation status information of the production unit equipment.

[0118] The control system determines or predicts equipment failure based on the operating status information, and if an equipment failure is determined or predicted, issues a warning message and notifies maintenance personnel to carry out operation and maintenance, thereby ensuring that the equipment is operating normally.

[0119] In some embodiments, the sub-control system determines or predicts equipment failure based on the operating status information, and when it determines or predicts equipment failure, notifies the control system, which then issues a warning message and notifies maintenance personnel to perform operation and maintenance, ensuring that the equipment is operating normally.

[0120] In some embodiments, the production unit condition detection module includes sensors for temperature, pressure, vibration, humidity, airtightness, piezoresistance, and the like.

[0121] In some embodiments, the production units include unit lighting fixtures that are constantly turned off, saving significant amounts of energy and significantly reducing the energy consumption of the production system.

[0122] A unit lighting fixture is located above each production unit, and when the unit lighting fixture is turned on, it illuminates the corresponding production unit.

[0123] When the control system determines or predicts that a production unit facility has failed, it turns on the unit lighting facility corresponding to the production unit, facilitating operation and maintenance by maintenance personnel.

[0124] In some embodiments of FIG. 6, the control system exchanges data with each sub-control system, and each sub-control system monitors its own system.

[0125] The control system determines demand information, establishes production processes, coordinates material transportation and replenishment of rejected materials, monitors production, issues abnormality warnings, controls energy saving, and tracks quality.

[0126] At the same time, an intelligent display board can be installed, and relevant information can be transmitted to the intelligent display board for real-time display.

[0127] In some embodiments, a method for producing an air conditioner in an air conditioner production, operation, and maintenance system includes: Obtain air conditioner demand information. The production process is determined based on the air conditioner demand information. The operating states of the heat exchanger general-purpose production system, the indoor unit production system, and the outdoor unit production system are controlled according to the production process. When the outdoor unit is produced in the production process, the outdoor heat exchanger fin production unit, the general-purpose production unit, and the bending unit are controlled to produce the outdoor heat exchanger, and the outdoor unit production system is controlled to produce the outdoor unit. When the indoor unit is produced in the production process, the indoor heat exchanger fin production unit and the general-purpose production unit are controlled to produce the indoor heat exchanger, and the indoor unit production system is controlled to produce the indoor unit.

[0128] In some embodiments, the required quantity of indoor units and the required quantity of outdoor units corresponding to the model of air conditioner to be produced are determined based on the air conditioner demand information, and the quantity n of indoor heat exchangers to be continuously produced is determined. The production process is as follows. The general-purpose heat exchanger production system is controlled to first produce one outdoor heat exchanger and supply it to the outdoor unit production system, and then produce n indoor heat exchangers and supply them to the indoor unit production system. If the number of indoor units reaches the required number of indoor units but the number of outdoor units does not reach the required number of outdoor units, the production process is changed and the heat exchanger general-purpose production system is controlled to produce outdoor heat exchangers for the outdoor unit production system. If the number of outdoor units reaches the required number of outdoor units but the number of indoor units does not reach the required number of indoor units, the production process is changed and the heat exchanger general-purpose production system is controlled to produce indoor unit heat exchangers and supply them to the indoor unit production system, where n is a natural number.

[0129] The above control method can effectively reduce the increase in energy consumption caused by no-load operation of the production line, facilitate the loading and unloading of goods, and improve management efficiency.

[0130] In some embodiments, the method for determining the number n of indoor heat exchangers to be continuously produced sets the number n of indoor units included in one air conditioning system as the number n of indoor heat exchangers to be continuously produced.

[0131] In some embodiments, a method for determining the number n of indoor heat exchangers to be continuously produced includes: The time t3 for producing the indoor units and the time t4 for producing the outdoor units are determined based on the model of air conditioner to be produced, and the time t4 for producing the outdoor units is divided by the time t3 for producing the indoor units, and then converted into an integer to determine n.

[0132] In some embodiments, when the production process produces an outdoor heat exchanger, the outdoor heat exchanger fin production unit is controlled to produce the outdoor heat exchanger fins, the tube bending unit of the general-purpose production unit cuts the tube at a first cutting operation position, the operating frequency of the tube expanding unit of the general-purpose production unit is a first frequency, and the bending unit bends the unbent outdoor heat exchanger.

[0133] When the production process is to produce an indoor heat exchanger, the indoor heat exchanger fin production unit is controlled to produce indoor heat exchanger fins, the tube bending unit of the general-purpose production unit cuts the tube at the second cutting operation position, the operating frequency of the tube expanding unit of the general-purpose production unit is the second frequency, and the bending unit does not operate.

[0134] The length of the tube cut at the first cutting position is the length of the outdoor heat exchanger tube, the length of the tube cut at the second cutting position is the length of the indoor heat exchanger tube, and the second frequency is less than or equal to the first frequency.

[0135] The following is the theoretical derivation of the output threshold. (1) Derivation of the equation for overcoming frictional force due to the relative movement between the tube expansion device and the copper tube wall. Contact area: Area where the cylindrical surface expands to a rectangle: A=2πr i L (1) pressure: F positive =p 2πr i L (2) Friction force: F f = μ F positive =2πL p r i μ (3) p (Pa) is the contact pressure of the expansion head on the copper pipe (positive pressure per unit area), r i (m) is the initial inner radius of the copper tube, L (m) is the contact length between the expansion device and the copper tube, and μ is the friction coefficient. (2) The derivative of the plastic deformation force is the energy required for the radial expansion of the copper tube, i.e., material yielding, and other effects. In the plastic phase, according to the Tresca yield criterion, σ θ -σ r is the yield strength of the material σ y The material yields when the circumferential stress σ θ Meet the following. σ θ -σ r =σ y (4) The radial stress is much smaller than the hoop stress (σ r ≪σ θ ), this approximation has a governing stress of σ θ≒σ y (5) σ r is the radial stress, σ y is the yield strength of the copper pipe, r o (m) is the outer radius after expansion, and r(m) is the average radius of the deformation region. Assuming the following:

number

number

number

number

[0136] This results in a threshold calculation of approximately 2750N for the expansion power, with forces below this value corresponding to the primary expansion force range and consistent with the primary expansion power of the production line equipment, and forces above this value corresponding to the secondary expansion force range and consistent with the secondary power. This formula guides the selection of the expansion machine and optimization of the machine power, after which the control system switches between the corresponding expansion device and the corresponding frequency to meet the expansion task. In some embodiments, forces below 2750N correspond to the secondary power of the equipment, and forces above 2750N correspond to the primary power.

[0137] In some embodiments, a method for obtaining air conditioner demand information includes: obtaining an order and obtaining air conditioner demand information based on the order; And / or, predicting air conditioner demand information for future time periods based on historical data.

[0138] By linking the production process with user requirements, information can be transmitted in real time, and user orders can drive coordinated manufacturing and precise matching between work locations, forming a mode of order-based production and flexible manufacturing, and quickly responding to diversified user requirements.

[0139] By predicting air conditioner demand information for future time periods based on historical data, production can be started in advance to meet market demand as quickly as possible.

[0140] In some embodiments, an overhead crane of the transport system identifies a material storage location and loads the material; The overhead crane identifies the location of the target unit shelf and transfers the material to the target unit shelf; The quantity of material on the unit shelf is detected, and when the quantity of material falls below a threshold, the conveying system is controlled to convey the material.

[0141] In some embodiments, if the detection unit fails the detection result, the transport system transports the material before the detection unit and reproduces the material before the detection unit.

[0142] In some embodiments, the transport system transmits transported heat exchanger material information to the control system; The end plate information creation unit of the heat exchanger general production system forms a unique identifier of each end plate as end plate information and creates it on the end plate, and the control system obtains the end plate information; The pallet information creation unit of the indoor unit production system or the outdoor unit production system creates a unique identifier for each pallet as pallet information on the pallet, and the control system acquires the pallet information; The control system associates end plate information, pallet information, and transported material information, and records production product information and production process information, creating a transparent production process and facilitating product quality tracking.

[0143] In some embodiments, the control system sends the transported material information to an end plate information creation unit, and the end plate information creation unit forms the material information and a unique identifier as end plate information and creates it on the end plate, so that if a malfunction occurs during use of the air conditioner, the end plate information can be scanned to facilitate quality tracking.

[0144] In some embodiments of FIG. 8, the method for producing an air conditioner includes the following steps.

[0145] S1: Obtain air conditioner demand information.

[0146] S2: Determine the production process based on the air conditioner demand information.

[0147] The production process includes the production process of a general-purpose heat exchanger production system, and in some embodiments, the production cycle is repeated, with one outdoor heat exchanger being produced followed by n indoor heat exchangers, and one outdoor heat exchanger being produced followed by n indoor heat exchangers, and the production process is changed when the number of indoor units or outdoor units reaches the required number.

[0148] If the number of indoor units reaches the required number of indoor units but the number of outdoor units does not reach the required number of outdoor units, the production process is changed and the general-purpose heat exchanger production system is controlled to produce outdoor heat exchangers for the outdoor unit production system, and is stopped when the required number of outdoor units is reached.

[0149] If the number of outdoor units reaches the required number for outdoor units but the number of indoor units does not reach the required number for indoor units, the production process is changed and the general-purpose heat exchanger production system is controlled to produce indoor unit heat exchangers and supply them to the indoor unit production system, and is stopped when the number of indoor units reaches the required number for indoor units.

[0150] S3: The conveying system conveys the material.

[0151] S4: If it is determined that the outdoor unit is to be produced based on the production process, proceed to step S5; if not, proceed to step S9.

[0152] S5: Input materials in order according to the outdoor heat exchanger production process to produce the outdoor heat exchanger.

[0153] During the production process, the end plate information creation unit creates end plate information on the end plate and uploads it to the control system. The information acquisition module acquires the end plate information and uploads it to the control system. The control system can determine the end plate position based on the information acquisition module.

[0154] The detection unit detects whether the product passed or failed, and if so, proceeds to the next process. If the product failed, the result is output via a rejected product conveying line and notifying the control system. The control system controls the conveying system to convey all materials from the upstream process of the detection unit (including its own system and upstream systems).

[0155] S6: The AGV transfers the outdoor heat exchanger to the outdoor unit production system, and inputs materials sequentially according to the outdoor unit production process to produce the outdoor unit.

[0156] During the production process, the pallet information creation unit creates pallet information on the pallet and uploads it to the control system. The information acquisition module acquires the pallet information and uploads it to the control system. The control system can determine the pallet position based on the pallet information acquisition module.

[0157] The detection unit detects whether the product passed or failed, and if so, proceeds to the next process. If the product failed, the result is output via a rejected product conveying line and notifying the control system. The control system controls the conveying system to convey all materials from the upstream process of the detection unit (including its own system and upstream systems).

[0158] S7: The AGV transfers the outdoor unit to the packaging system, and the outdoor unit packaging materials are added sequentially according to the packaging process to pack it.

[0159] During the production process, the packing pallet information creation unit creates packing pallet information on the pallet and uploads it to the control system. The information acquisition module acquires the packing pallet information and uploads it to the control system. The control system can determine the packing pallet position based on the packing pallet information acquisition module.

[0160] The control system creates production information formed from material information, supplier information, production product information, production process information, etc. related to end plate information as a production label and places it on the packaging.

[0161] The detection unit detects whether the product passed or failed, and if so, proceeds to the next process. If the product failed, the product is output via a reject conveyor line and notified to the control system. The control system controls the conveyor system to convey all materials from the process upstream of the detection unit in the packaging system.

[0162] S8: The AGV transfers the packaged outdoor unit to the finished unit storage system.

[0163] Proceed to step S4.

[0164] S9: Input materials in order according to the indoor heat exchanger production process to produce the indoor heat exchanger.

[0165] During the production process, the end plate information creation unit creates end plate information on the end plate and uploads it to the control system. The information acquisition module acquires the end plate information and uploads it to the control system. The control system can determine the end plate position based on the information acquisition module.

[0166] The detection unit detects whether the product passed or failed, and if so, proceeds to the next process. If the product failed, the result is output via a rejected product conveying line and notifying the control system. The control system controls the conveying system to convey all materials from the upstream process of the detection unit (including its own system and upstream systems).

[0167] S10: The AGV transfers the indoor heat exchanger to the indoor unit production system, and inputs materials in sequence according to the indoor unit production process to produce the indoor unit.

[0168] During the production process, the pallet information creation unit creates pallet information on the pallet and uploads it to the control system. The information acquisition module acquires the pallet information and uploads it to the control system. The control system can determine the pallet position based on the pallet information acquisition module.

[0169] The detection unit detects whether the product passes or fails. If it passes, it proceeds to the next process. If it fails, it outputs the product via a rejected product conveying line and notifies the control system. The control system controls the conveying system to transport all materials from the upstream processes of the detection unit (including its own system and upstream systems). In some embodiments, before production begins, the control system commands the conveying system (such as an overhead crane material transport system) to transport m sets of complete production materials from the material storage system to each unit shelf of the corresponding production system (the indoor unit production system and its upstream general-purpose heat exchanger production system) based on a determined production plan (e.g., to produce m indoor units). During production, if a detection unit (e.g., a welding appearance inspection unit or an airtightness inspection unit) in a production system detects a rejected product, the system immediately initiates the following parallel operation: That is, the rejected product is immediately directed to a dedicated rejected product conveying line and output from the main production process to avoid affecting or blocking subsequent processes. At the same time, the detection unit immediately uploads data, including information such as the product's identity, reject type, and location, to the control system.

[0170] After receiving the rejection information, the control system executes a material replenishment command rather than interrupting the ongoing production plan. It instructs the transport system to transport additional materials required for the detection unit and all upstream processes to the corresponding unit shelf. For example, if a rejection is detected at the indoor unit pipe welding station, the control system commands the replenishment of materials for all upstream processes, such as heat exchangers, pipes, and valves. The production line continues production according to the original takt time until the production tasks for all m products in the initial plan are completed. This design prevents a single rejected product from affecting the operating efficiency and planning of the entire production line. After the initial production plan is completed, the control system automatically initiates a replenishment production mode based on the previously recorded number of rejected products (the process is shown in Figure 9). It uses the previously replenished materials to produce the corresponding number of passing products as needed to make up for the quantity shortage caused by the rejected products. This reject processing mechanism is cyclical. If a total of k defective products are detected during the production of m products, the control system will issue k "material replenishment" commands in succession to prepare k sets of replenishment materials for the production line. After the initial plan is completed, the replenishment production mode will be executed k times in succession, ensuring that m qualified products are finally delivered.

[0171] S11: The AGV transfers the indoor unit to the packaging system, and packs it by sequentially adding packaging materials for the indoor unit according to the packing process.

[0172] During the production process, the packing pallet information creation unit creates packing pallet information on the pallet and uploads it to the control system. The information acquisition module acquires the packing pallet information and uploads it to the control system. The control system can determine the packing pallet position based on the packing pallet information acquisition module.

[0173] The control system creates production information formed from material information, supplier information, production product information, production process information, etc. related to end plate information as a production label and places it on the packaging.

[0174] The detection unit detects whether the product passed or failed, and if so, proceeds to the next process. If the product failed, the product is output via a reject conveyor line and notified to the control system. The control system controls the conveyor system to convey all materials from the process upstream of the detection unit in the packaging system.

[0175] S12: The AGV transfers the packed indoor units to the finished unit storage system.

[0176] Proceed to step S4.

[0177] In some embodiments of FIG. 9, if the detection unit detects a failure, the production process is adjusted.

[0178] S1: A failure is detected by the detection unit.

[0179] S2: Control the transport system to transport the relevant materials to the pre-process of the detection unit.

[0180] S3: Determine whether the detection unit is an indoor unit-related detection unit or an outdoor unit-related detection unit.

[0181] The indoor unit-related detection units include detection units of an indoor unit production system and an indoor heat exchanger production system, and the outdoor unit-related detection units include detection units of an outdoor unit production system and an outdoor heat exchanger production system.

[0182] S4: Obtain whether the heat exchanger general-purpose production system is currently producing indoor heat exchangers or outdoor heat exchangers.

[0183] S5: Determine whether the current production status of the general-purpose heat exchanger production system matches the heat exchanger corresponding to the rejected product. If it matches, proceed to step S6; if it does not match, proceed to step S7.

[0184] S6: Reproduce.

[0185] S7: The production status of the general-purpose heat exchanger production system is switched to the heat exchanger corresponding to the rejected product.

[0186] S8: Reproduce.

[0187] In some embodiments, detecting operational status information of production unit equipment; Equipment failure is determined or predicted based on the operating status information.

[0188] In some embodiments, controlling the lighting fixtures of the production unit to be always off; When it is determined or predicted that a production unit facility has failed, the unit lighting facility corresponding to the production unit is turned on.

[0189] 10 to 13, both the indoor heat exchanger fin production unit and the outdoor heat exchanger fin production unit include fin loading and unloading equipment, which includes a loading and unloading holder 410, a support base plate 420, a lifting support plate 430, and a downline robot 450. The loading and unloading holder 410 is an overall frame structure with a storage position formed therein. The support base plate 420 is horizontally installed on the loading and unloading holder 410, specifically, located at the bottom of the storage position formed within the loading and unloading holder 410.

[0190] A drop pin 61 is installed vertically on the support base plate 420, with the bottom of the drop pin 61 fixed to the support base plate 420 and the top of the drop pin 61 installed vertically upward, which is used to position the fin that drops into the storage position after processing and molding.

[0191] The length direction of the fin is defined as the first direction, the width direction of the fin as the second direction, and the thickness direction of the fin as the third direction. Along the second direction, the fins in the storage position form multiple groups of fin stacks 60, and each group of fin stacks 60 includes multiple fins stacked on drop pins 61 along the third direction.

[0192] In combination with FIG. 14, a downline robot 450 is used to transfer each group of fin stacks 60 onto the roller transfer line.

[0193] Lifting support plate 430 is installed parallel to and above support bottom plate 420, and is connected to loading / unloading holder 410 so as to be movable in the third direction, and communication holes 432 are formed on lifting support plate 430. Through-holes are formed on the fins, and drop pins 61 are connected to the corresponding insertion holes via communication holes 432.

[0194] An elevating cylinder 440 is installed on the take-in / take-out holder 410 , and the output end of the elevating cylinder 440 is connected to the elevating support plate 430 to drive the elevating support plate 430 to move in the height direction of the take-in / take-out holder 410 .

[0195] When lifting support plate 430 moves up and down in the third direction, drop pin 61 remains fixed, and insertion hole and communication hole 432 move up and down relative to drop pin 61 .

[0196] After the fin stack 60 is formed in the storage position, further locating pins 62 are placed on the fin stack 60 .

[0197] The positioning pin 62 is installed in the reserved insertion hole, one end of the positioning pin 62 is supported on the lift support plate 430 and the other end extends above the fin stack 60.

[0198] No through holes 432 are designed at the positions where the lifting support plate 430 and the positioning pin 62 correspond, and as the lifting support plate 430 moves up and down, the positioning pin 62 also moves, always penetrating and holding each fin in the fin stack 60 of the same group.

[0199] Referring to FIG. 14, the downline robot 450 includes a downline robot body 451 and a downline fixture 452 , and the downline fixture 452 is installed on the downline robot body 451 .

[0200] The downline robot body 451 includes a downline robot base 4511, a downline robot arm 4512, and a downline robot forearm 4513, which are connected in series.

[0201] In addition, the downline robot 450 further includes a robot motor and a vision camera, the downline robot base 4511 is fixed to the ground with bolts, the robot motor is connected to the downline robot base 4511 with bolts, the downline robot base 4511, the downline robot arm 4512, and the downline robot forearm 4513 are all connected via sliding joints, and the vision camera is installed on the downline jig 452 and is used to acquire position information of the fin stack 60.

[0202] Referring to Figures 15 to 17, the downline jig 452 includes a first downline holding member 4521 and a second downline holding member 4522 arranged symmetrically, and holding portions are installed on the first downline holding member 4521 and the second downline holding member 4522, respectively, which are used to hold both ends of the positioning pin 62.

[0203] The downline robot 450 is configured to grip both ends of the fin stack 60 on the lifting support plate 430 and move it to a target position, that is, to grip the fin stack 60 and move it onto the roller transport line.

[0204] Along the length of each fin, at least one positioning pin 62 is inserted at each end of the fin stack 60, the bottom of the positioning pin 62 contacts the lifting support plate 430, and the top of the positioning pin 62 extends to the upper end of the fin stack 60. The first downline gripping member 4521 and the second downline gripping member 4522 are used to grip the upper end of the positioning pin 62 and the bottom end of the positioning pin 62, respectively.

[0205] The first downline gripping member 4521 and the second downline gripping member 4522 are each connected to the end of the downline robot forearm 4513 via a gripping power member, the first downline gripping member 4521 includes two first downline gripping claws spaced apart, and the second downline gripping member 4522 includes two second downline gripping claws spaced apart, the first downline gripping claws are used to grip the upper end of the positioning pin 62, and the second downline gripping claws are used to grip the bottom end of the positioning pin 62.

[0206] The number of gripping force members may be two, and each gripping force member includes one output end connected to the first downline gripping claw and the second downline gripping claw, respectively.

[0207] Alternatively, the number of gripping power members is one, and the gripping power members have two output ends, which are located on both sides of the gripping power member and connected to the first downline gripping claw and the second downline gripping claw, respectively.

[0208] The first downline gripping claw and the second downline gripping claw are each connected to the gripping power member via an adapter plate 4523. That is, the output end of the gripping power member is connected to the adapter plate 4523, and the first downline gripping claw and the second downline gripping claw are each connected and fixed to the adapter plate 4523 on the corresponding side.

[0209] A first positioning clamp plate perpendicular to the adapter plate 4523 is formed on the first downline gripping claw, and at least one first positioning recess opening toward the second downline gripping claw is formed on the first positioning clamp plate.

[0210] A second positioning clamp plate 4524 perpendicular to the adapter plate 4523 is formed on the second downline gripping claw, and at least one second positioning recess 4525 opening toward the first downline gripping claw is formed on the second positioning clamp plate 4524.

[0211] In the gripped state, the top end of the positioning pin 62 is inserted into the first positioning recess, and the bottom end of the positioning pin 62 is inserted into the second positioning recess 4525 .

[0212] The first downline gripping claw further includes a first connecting plate, which is installed perpendicular to the first positioning clamp plate, and the first positioning clamp plate is detachably connected to the adapter plate 4523 via the first connecting plate.

[0213] The second downline gripping claw further includes a second connecting plate 4527, which is installed vertically to the second positioning clamp plate 4524, and the second positioning clamp plate 4524 is detachably connected to the adapter plate 4523 via the second connecting plate 4527.

[0214] The first connecting plate and the first positioning clamp plate are integrally formed, and the second connecting plate 4527 and the second positioning clamp plate 4524 are integrally formed. Reinforcing ribs 4528 are installed between the first connecting plate and the first positioning clamp plate and between the second connecting plate 4527 and the second positioning clamp plate 4524, respectively, to increase the connection strength between the first connecting plate and the first positioning clamp plate, and between the second connecting plate 4527 and the second positioning clamp plate 4524.

[0215] A guide slope 4526 is formed on the end of the second positioning clamp plate 4524 corresponding to the bottom end of the fin stack 60, and the guide slope 4526 is used to lift the bottom fin of the fin stack 60 and guide the bottom end of the positioning pin 62 into the second positioning recess 4525 when the second downline gripping claw moves to the bottom of the fin stack 60.

[0216] To facilitate gripping of the second positioning clamp plate 4524, in some embodiments of FIG. 13, an upwardly extending support protrusion 431 is formed on the lifting support plate 430, and the length of the support protrusion 431 along the first direction is smaller than the length of the fin.

[0217] Each fin stack 60 is supported on the support protrusion 431, and due to the action of the support protrusion 431, a gripping gap is formed between the bottom of each fin stack 60 and the lifting support plate 430, and the second downline gripping member 4522 moves from the gripping gap to the bottom of the fin stack 60 and grips the positioning pin 62.

[0218] In order to avoid interference between the adapter plate 4523 on the second positioning clamp plate 4524 and the support protrusion 431 during the clamping process, the present application designs the second connecting plate 4527 to extend its length downward, so that the adapter plate 4523 is positioned above the support protrusion 431 during the clamping process of the second positioning clamp plate 4524, thereby avoiding interference.

[0219] Referring to Figures 18 to 20, the tube insertion unit has an end plate mounting position and an end plate mounting facility, and the end plate mounting facility fits to the end plate mounting position.

[0220] The end plate mounting equipment includes an end plate mounting robot 510 and lift stop members 520. The end plate mounting robots 510 are installed symmetrically on both sides of the roller conveying line and are used to mount end plate members 63 on both ends of the fin stack 60 simultaneously.

[0221] Each end plate mounting robot 510 includes an end plate robot body 511, a connecting center beam 512, a gripping force member, and two end plate jigs 513, the connecting center beam 512 being installed on the end plate robot body, the gripping force member being installed on the connecting center beam 512, and the two end plate jigs 513 being installed on the gripping force member, and under the action of the gripping force member, the two end plate jigs 513 move toward each other or in opposite directions to grip or release the end plate member 63.

[0222] The gripping force member is arranged along the length of the connecting center beam 512, and has a first telescopic end and a second telescopic end, and two end plate jigs 513 are respectively installed at the first telescopic end and the second telescopic end.

[0223] Alternatively, in another embodiment, the gripping force members and the end plate jigs 513 have a one-to-one correspondence, and the two gripping force members are respectively installed symmetrically on the connecting center beam 512, and the end plate jigs 513 are installed at the output ends of the gripping force members.

[0224] An end plate attachment position is formed on the roller conveyor line, and the stopper 522 is located downstream of the end plate attachment position. As the fin stack 60 is conveyed along the roller conveyor line to the end plate attachment position, the stopper 522 rises above the roller 4101.

[0225] The lift stop member 520 is installed on the roller conveying line, and before the fin stack 60 is conveyed to the end plate attachment position, the lift stop member 520 rises to stop the fin stack 60.

[0226] The lifting stop member 520 specifically includes a lifting drive member 521 and a stop portion 522. The lifting drive member 521 is used for installation below the roller conveying line, and the stop portion 522 is installed at the output end of the lifting drive member 521. Through the action of the lifting drive member 521, the stop portion 522 moves up and down between the corresponding adjacent rollers 4101 on the roller conveying line, and is used to stop and correct the position of the fin stack 60 at the corresponding position on the roller conveying line.

[0227] The stop portion 522 includes two or more stop blocks spaced apart along the axial direction of the roller 4101, and the two stop blocks are both connected to the output end of the lifting drive member 521, which simultaneously lifts the two stop blocks so that before the fin stack 60 is transported to the end plate mounting position, the two stop blocks rise above the roller 4101 and stop the fin stack 60 from being transported forward.

[0228] If there is an angular deviation between the fin stack 60 and the roller 4101, the stop block corrects the fin stack 60 so that it is parallel to the axial direction of the roller 4101, making it easier for the end plate robot to attach the end plate member 63.

[0229] An end plate gripping position is formed between two end plate jigs 513 of end plate mounting robot 510, and a pusher member 514 extending toward the end plate gripping position is installed on connecting center beam 512. Pusher member 514 includes a pusher power member and a pusher end, the pusher power member being fixed to connecting center beam 512 and the pusher end being fixed to the output end of the pusher power member.

[0230] A pallet 4102 is further installed on the roller conveying line, and the fin stack 60 is placed on the pallet 4102. The jack-up member 530 is installed upstream of the lifting stop member 520 and includes a jack-up cylinder and a jack-up block, the jack-up cylinder is installed below the end plate mounting position, and the jack-up block is installed at the output end of the jack-up cylinder, and by the action of the jack-up cylinder, the jack-up block rises and falls between the corresponding rollers 4101, and is used to lift the pallet transported to the jack-up block installation position.

[0231] If the conveying direction of the roller conveying line is defined as the X direction, the width direction of the roller conveying line as the Y direction, and the height direction of the roller conveying line as the Z direction, and the dimension of the end plate member 63 along the Z direction is defined as the width of the end plate member 63, and the dimension of the fin stack 60 along the Z direction is defined as the width of the fin stack 60, then the width L1 of the end plate member 63 is greater than the width L2 of the fin stack 60, and the thickness L3 of the pallet 4102 satisfies L3 > (L1 - L2) / 2, so that the end plate members 63 do not interfere with the rollers 4101 when attached to both ends of the fin stack 60.

[0232] A detection member 550 is further installed upstream of the end plate mounting position, and is specifically installed on the support frame 50 and located on one side of the roller 4101. The detection member 550 is connected to a heat exchanger sub-control system, and the heat exchanger sub-control system is signal-connected to the lifting drive member 521 and the jack-up cylinder. The heat exchanger sub-control system receives the detection signal from the detection member 550 and is used to control the operation of the lifting drive member 521 and the jack-up cylinder.

[0233] The heat exchanger sub-control system is the control center of the general-purpose heat exchanger production system, and is used to control the start and stop of the roller conveyor line, the work of each robot, and the switches of each piece of equipment.

[0234] In another embodiment, an alignment assembly 540 is further installed on the roller conveying line, and the alignment assembly 540 includes two alignment beams 541 installed symmetrically on the roller conveying line, the alignment beams 541 are located downstream of the end plate mounting positions, and an alignment channel is formed between the alignment beams 541, which is used to align the pallet to an intermediate position on the roller conveying line.

[0235] A guide portion 542 is provided at one end of each alignment beam 541 close to the end plate mounting position, and a guide channel that gradually narrows along the conveying direction of the fin stack 60 is formed between the two guide portions 542.

[0236] The alignment beam 541 is fixed to the support frame 50 via an alignment bracket 543, and the height of the alignment beam 541 is lower than the positioning pins 62 on the fin stack.

[0237] After the end plate attachment is complete, the stop block on the lift stop member 520 is lowered, and the fin stack 60 continues to be conveyed downstream along the roller conveying line.

[0238] After the end plate members 63 at both ends of the fin stack 60 pass through the guide channel, the fin stack 60 moves toward the middle position of the roller conveying line through the action of the guide portion 542, thereby improving the positional accuracy of the fin stack 60 during transportation and making it easier for the tube insertion robot 610 to operate during subsequent tube insertion.

[0239] A plurality of limit protrusions are provided on each of the opposing sides of the two end plate jigs 513, and a gripping position that restricts the end plate member 63 is formed between the limit protrusions of each end plate jigs 513. When gripped, the end of the end plate member 63 is positioned between the limit protrusions, restricting the position of the end plate member 63 and preventing the end plate member 63 from falling off the end plate jig 513.

[0240] 20-23, similar to the downline robot body 451, the endplate robot body 511 includes an endplate robot base, an endplate robot arm, and an endplate robot forearm connected in series.

[0241] In addition, the end plate robot also includes a robot motor and a vision camera, the end plate robot base is fixed to the ground with bolts, the robot motor is connected to the end plate robot base via bolts, the end plate robot base, the end plate robot arm, and the end plate robot forearm are all connected via sliding joints, and the vision camera is installed on the end plate jig 513 and is used to obtain the position information of the fin stack 60 and the positioning pin 62.

[0242] The end plate members 63 also have through holes that correspond one-to-one with the fins, and the end plate members 63 are inserted onto the positioning pins 62 through the corresponding through holes. After the end plate members 63 have been inserted, the extrusion power member drives the extrusion end to push the end plate members 63 forward, simultaneously pushing the end plate members 63 on both sides toward the middle, attaching the end plate members 63 to a predetermined position and eliminating gaps between the fins, so that the fins are tightly connected to each other.

[0243] After the attachment is completed, the fin stack 60 is transported downstream along the roller transport line and reaches the pipe insertion work position.

[0244] A pipe insertion device is installed beside the pipe insertion work position, and the pipe insertion device grips the pipe line member and inserts the pipe line member into the insertion hole in the fin stack 60.

[0245] Referring to Figures 24 to 29, the nitrogen filling unit includes a nitrogen filling device 710, a nitrogen filling docking member 720, and a nitrogen filling robot 730, wherein the nitrogen filling device 710 is connected to an external nitrogen filling pipeline 711, the nitrogen filling docking member 720 is installed at the end of the nitrogen filling pipeline 711, and a connecting channel is formed within the nitrogen filling docking member 720 that gradually widens in the direction away from the nitrogen filling pipeline 711.

[0246] The nitrogen filling robot 730 includes a nitrogen filling robot body 731 and a nitrogen filling jig 732. The nitrogen filling robot 730 is installed to the side of the nitrogen filling work position on the roller conveying line, and the nitrogen filling jig 732 is installed on the nitrogen filling robot 730. The nitrogen filling jig 732 is configured to grasp the nitrogen filling docking member 720 and connect it to the pipeline member on the fin stack 60, and to fill nitrogen into the pipeline member.

[0247] In some embodiments, the nitrogen filling device 710 is installed within a nitrogen filling chamber 740 , the nitrogen filling chamber 740 is provided with an access port, and the nitrogen filling line 711 extends from the access port to the exterior of the nitrogen filling chamber 740 .

[0248] The nitrogen filling chamber 740 is supported by legs directly above the nitrogen filling operation position, an attachment port is installed on the bottom wall of the nitrogen filling chamber 740, the nitrogen filling pipe 711 extends from directly below the nitrogen filling chamber 740, and the nitrogen filling docking member 720 is connected to the nitrogen filling pipe 711.

[0249] Specifically, referring to Figures 23 and 24, in some embodiments of the present application, nitrogen-filled docking member 720 is detachably connected to nitrogen-filled conduit 711, and one end of nitrogen-filled docking member 720 that connects to nitrogen-filled conduit 711 is provided with a connecting end, an internal thread is formed on the inner wall of the connecting end, and an external thread is formed on the end of nitrogen-filled conduit 711, and nitrogen-filled conduit 711 is threadedly connected into the connecting end.

[0250] During the nitrogen filling process, the nitrogen filling robot 730 grasps the nitrogen filling pipeline 711 above the nitrogen filling docking member 720, pulls the nitrogen filling pipeline 711 downward, and moves it onto the pipeline member, which is led into the nitrogen filling pipeline 711 through the nitrogen filling docking member 720 and connects to the nitrogen filling pipeline 711. The nitrogen filling device 710 then sends nitrogen gas into the pipeline member.

[0251] To ensure that the conduit member is guided into the nitrogen-filled conduit 711 , the minimum inner diameter within the connecting channel is equal to or less than the inner diameter of the nitrogen-filled conduit 711 .

[0252] Referring to FIG. 29, in another embodiment, the nitrogen fill docking member 720 and the nitrogen fill line 711 are integrally molded, and the nitrogen fill docking member 720 has a generally horn-shaped configuration.

[0253] 30, in another embodiment, an elastic member 750 is designed to be installed between the nitrogen filling conduit 711 and the nitrogen filling chamber 740 so that the nitrogen filling conduit 711 automatically returns to its upward position after nitrogen filling. One end of the elastic member 750 is fixed to the inner wall of the nitrogen filling chamber 740, and the other end is connected to the nitrogen filling conduit 711 inside the nitrogen filling chamber 740. When the nitrogen filling conduit 711 moves outward and connects to the conduit member 64, the elastic member 750 is compressed. After nitrogen filling is completed, when the nitrogen filling robot 730 releases the nitrogen filling conduit 711, the elastic member 750 raises and returns the nitrogen filling conduit 711 by the action of its own restoring force.

[0254] In another embodiment, an elastic member 750 is installed between the nitrogen filling pipeline 711 and the nitrogen filling chamber 740, one end of the elastic member 750 is fixed to the outside of the mounting port, and the other end is connected to the nitrogen filling pipeline 711 outside the nitrogen filling chamber 740. When the nitrogen filling pipeline 711 moves outward and connects to the pipeline member 64, the elastic member 750 is pulled, and when the nitrogen filling robot 730 releases the nitrogen filling pipeline 711 after nitrogen filling is completed, the elastic member 750 raises and returns the nitrogen filling pipeline 711 by the action of its own restoring force.

[0255] In another embodiment, an elastic conduit portion is formed on the nitrogen filling conduit 711, allowing the nitrogen filling conduit 711 to expand and contract relative to the attachment port.

[0256] The elastic pipe line portion is at least a part of the nitrogen filling pipe line 711, and when nitrogen is filled, the elastic pipe line portion is extended, and after nitrogen filling is completed, the elastic pipe line portion contracts due to its own elastic action, causing the nitrogen filling docking member 720 to rise and return to its original position.

[0257] The nitrogen filling jig 732 includes a gripping drive member and a gripping claw assembly 733 connected to the gripping drive member, and the gripping claw assembly 733 includes a first gripping claw 7331 and a second gripping claw 7332 arranged symmetrically, and gripping recesses 7333 are formed on the first gripping claw 7331 and the second gripping claw 7332, respectively, and the dimensions of the gripping recesses 7333 are compatible with the outer diameter of the nitrogen filling pipe 711, and the nitrogen filling pipe 711 is used to be gripped between the gripping recesses 7333.

[0258] The specific connection between the gripping drive member and the first gripping claw 7331 and the second gripping claw 7332, and the realization of opening and closing the first gripping claw 7331 and the second gripping claw 7332 are conventional technologies, and will not be described in detail here.

[0259] Similarly, the nitrogen filling robot body 731 also includes a nitrogen filling robot 730 base, a nitrogen filling robot 730 arm, and a nitrogen filling robot 730 forearm, which are connected in series.

[0260] In addition, the nitrogen filling robot 730 also includes a robot motor and a vision camera, the base of the nitrogen filling robot 730 is fixed to the ground with bolts, the robot motor is connected to the base of the nitrogen filling robot 730 with bolts, the base of the nitrogen filling robot 730, the arm of the nitrogen filling robot 730, and the forearm of the nitrogen filling robot 730 are all connected via a sliding joint, and the vision camera is installed on the nitrogen filling jig 732 and is used to obtain the position information of the fin stack 60 and the positioning pin 62.

[0261] After the nitrogen filling is completed, the roller conveyor line conveys the fin stack 60 forward, where it is welded in a bending pipe welding unit.

[0262] In some embodiments, the production system includes a heat exchanger painting system 300 .

[0263] In some embodiments, the heat exchanger painting system 300 is installed in the indoor heat exchanger assembly unit of the indoor unit production system and in the outdoor heat exchanger assembly unit of the outdoor unit production system. After the heat exchangers are installed, they are painted. By incorporating the heat exchanger painting process into the indoor unit production line or the outdoor unit production line, the integration of the production line can be further enhanced.

[0264] 31 is a configuration diagram of a heat exchanger painting system 300. The painting system is configured to paint a heat exchanger.

[0265] 32 to 33, a heat exchanger includes heat exchange tubes configured to allow a refrigerant to flow through the heat exchange tubes. The heat exchanger further includes a plurality of fins 31 arranged at intervals, with any fin 31 having a through-hole 32 through which the heat exchange tubes pass. FIG. 32 shows a straight-type heat exchanger. Another type of heat exchanger is a U-shaped heat exchanger. Taking FIG. 32 as an example, the length direction of the heat exchanger is designated X, the width direction is designated Y, and the thickness direction is designated Z.

[0266] 31, the painting system includes a painting robot 310, and a spray head unit 311 is installed at the end of the manipulator of the painting robot 310, and the spray head unit 311 is configured to paint the fins 31. A first rail 370 is installed on the ground, and the painting robot 310 moves along the first rail 370.

[0267] During painting, the spray head 311 is located on one side of the heat exchanger and sprays paint from one side of the heat exchanger to the other side. The painting area can be controlled by controlling parameters such as the movement range and width of the spray head 311, the spray pressure of the spray head 311, and the distance between the spray head 311 and the heat exchanger.

[0268] The spray head 311 is a two-fluid atomizing nozzle with a nozzle diameter of 0.3 mm, which ensures that the atomized particle diameter is ≦10 μm and ensures that the surface of the fin 31 is uniformly coated.

[0269] The coating system further includes a paint tank configured to supply paint to the spray head portion 311, in which a capsule portion 380 is mixed, and inside the capsule portion 380, a repair agent is filled.

[0270] The painting system further includes a vision device 320 configured to capture image information of the heat exchanger.

[0271] The indoor unit sub-control system and the outdoor unit sub-control system communicate with the painting robot 310 and the vision device 320 in each system, and the control system is configured to analyze the image information of the heat exchanger to obtain dimensional data information of the heat exchanger and control the movement of the spray head unit 311.

[0272] The coating system further includes a magnetic field generator 360 configured to radiate a magnetic field to the heat exchanger.

[0273] The capsule portion 380 is configured to move in a direction approaching the through-hole 32 under the action of a magnetic field, and the capsule portion 380 is further configured to burst when subjected to an external force, releasing the repair agent inside and repairing the paint on the fin 31.

[0274] Specifically, the paint sprayed from the spray head 311 has a repair function, and the capsule 380 is mixed into the paint, and the capsule 380 is filled with a repair agent, which contains siloxane and a catalyst.

[0275] The outer diameter of capsule part 380 is at the nano level, and the particle size of capsule part 380 is 5 to 20 μm. Figure 34 is a structural diagram of capsule part 380, and the outer shell of capsule part 380 has a spherical core-shell structure, which ensures that it receives a uniform force under the action of a magnetic field.

[0276] The capsule portion 380 is made from iron trioxide and silicon dioxide. The capsule portion 380 uses iron trioxide nanoparticles and is coated with silicon dioxide using a sol-gel method to form a core-shell structure. The iron trioxide gives the capsule portion 380 high magnetic susceptibility, facilitating precise control of the movement trajectory using an external magnetic field. The silicon dioxide gives the capsule portion 380 chemical inertness and a certain mechanical strength, protecting the inner core from environmental corrosion, while adjusting the degree of cross-linking to control the rupture threshold of the outer shell.

[0277] Microfluidic technology is used to encapsulate the repair agent in the lumen of capsule part 380. When a crack occurs in fin 31 due to corrosion or mechanical load, a high-stress area is formed at the tip of the crack, and when the local stress, tensile stress, shear stress, etc. caused by the crack expansion exceed the mechanical strength threshold of the outer shell of capsule part 380, the outer shell of capsule part 380 ruptures, releasing the repair agent.

[0278] By adjusting the thickness and degree of cross-linking of the outer shell of the capsule part 380 or by adding a toughening agent, the mechanical strength and sensitivity of the outer shell are balanced, and the capsule part 380 is embedded in advance in the root part of the fin 31, an area that is prone to stress concentration during painting, thereby improving trigger efficiency.

[0279] The magnetic field generator 360 employs an electromagnetic array device, which generates a gradient magnetic field, and the capsule part 380 is driven by the magnetic force in the magnetic field, and gathers in the region of the root of the fin 31 (i.e., the position of the through-hole 32) where the magnetic field strength is high. The formula is as follows: F = ▽(M × B) F is the magnetic force (unit: N) that moves the capsule part, M is the magnetization strength (unit: A / m) of the capsule part 380, and B is the magnetic induction strength (unit: T) of the gradient magnetic field generated by the electromagnetic array device.

[0280] The electromagnetic array adjusts the magnetic field gradient according to the fin gap to ensure that the deposition of the capsule 380 is limited to the root region of the fin 31 that is prone to corrosion. The magnetic field adjustment satisfies the following equation: ▽B=k / d 2 ▽B is the magnetic field gradient (unit: T / m), k is the material-process coefficient (unit: Tm2 ), d is the fin gap width, i.e., the minimum distance between adjacent fins (unit: m).

[0281] When the fins 31 are processed, flanges are formed around the through holes 32, and the presence of the flanges minimizes the distance between two adjacent fins 31 at the positions of the through holes 32. Therefore, the magnetic field strength at the through holes 32, i.e., the roots of the fins 31, is maximized, and the capsule parts 380 move in a direction approaching the through holes 32 under the action of the magnetic field, and can be deposited near the through holes 32.

[0282] The root of the fin 31 is a location where corrosion is likely to occur. After the fin 31 corrodes, cracks appear on the surface. When the local stress, tensile stress, shear stress, etc. caused by the crack expansion exceed the mechanical strength threshold of the outer shell of the capsule part 380, the outer shell of the capsule part 380 bursts, releasing a repair agent, which further repairs the corroded location of the fin 31.

[0283] In some embodiments of the present application, the spray head 311 is located on one side of the heat exchanger, and the spray head 311 moves along a sinusoidal path in the length direction X of the heat exchanger while also moving in the width direction Y of the heat exchanger. Compared to the conventional segment coating method, this coating path is more efficient.

[0284] In some embodiments of the present application, when the spray head unit 311 moves in the Y direction, the spray head unit 311 oscillates back and forth in the Y direction, and the oscillation amplitude of the spray head unit 311 is directly proportional to the gap between two adjacent fins 31. The formula is as follows:

number

[0285] The lower limit of the oscillation amplitude of the spray head portion 311 is 0.5 mm, which is applicable to high density areas with d≦0.8 mm.

[0286] The upper limit of the oscillation amplitude of the spray head portion 311 is 3.0 mm, which is applied to the low density area where d≧2.5 mm.

[0287] In some embodiments of the present application, when the spray head portion 311 moves in the Y direction, the spray head portion 311 oscillates back and forth in the Y direction, and the oscillation frequency of the spray head portion 311 is directly proportional to the density of the fins 31. The formula is as follows: f=k f ρ where f is the oscillation frequency (unit: Hz) of the spray head portion 311, kf is the density-frequency coefficient (unit: Hz mm / fin 31), and ρ is the density of the fins 31, i.e., the number of fins 31 per unit length (unit: fin 31 / mm). The higher the density of the fins 31, the higher the oscillation frequency of the spray head portion 311, improving the paint coating efficiency.

[0288] As the coating pressure increases, the oscillation frequency of the spray head increases synchronously, matching the atomized particle output velocity.

[0289] The fundamental oscillation frequency of the spray head 311 is 5 Hz, and is applied to a low density area of ​​ρ≦10 fins 31 / cm.

[0290] The upper limit of the oscillation frequency of the spray head portion 311 is 20 Hz, which is applied to a high density area where ρ≧30 fins 31 / cm.

[0291] In some embodiments of the present application, the heat exchanger has straight and bent sections, and the spray head 311 paints the straight and bent sections separately.

[0292] In other words, in the case of a U-shaped heat exchanger, the spray head 311 paints the heat exchanger in sections, for example, first painting the straight section and then painting the bent section. When the spray head 311 passes through the bent section, it creates an arc-shaped or broken line detour along the outer edge of the bent section, ensuring that the spray head 311 and the bent section maintain a predetermined safety distance.

[0293] In some embodiments of the present application, the movement path of the spray head 311 is located within the projected area of ​​the heat exchanger, and the movement speed and oscillation amplitude of the spray head 311 are reduced as the spray head 311 approaches the boundary of the heat exchanger.

[0294] In other words, the vision device 320 extracts the boundary of the fin 31 in real time and generates a dynamic paint prohibition zone. The movement path of the spray head 311 is strictly limited within the projection range of the fin 31, and a gradient deceleration strategy is adopted in the edge region to reduce the movement speed and amplitude when approaching the boundary, thereby preventing paint from splashing.

[0295] In some embodiments of the present application, the heat exchanger coating system 300 further includes a UV curing device 340, which is configured to cure the coating on the heat exchanger after coating. The UV curing device 340 is a known technology and will not be described in detail in this application.

[0296] The heat exchanger coating system 300 further includes a third conveying line 390, with the magnetic field generating device 360 ​​and the UV curing device 340 spaced apart along the length of the third conveying line 390, and the magnetic field generating device 360 ​​generating a magnetic field on the heat exchanger placed on the third conveying line 390.

[0297] In some embodiments of the present application, the painting process of the heat exchanger painting system 300 includes:

[0298] The vision device 320 acquires point cloud data of the heat exchanger fins 31 and extracts topology parameters such as the inclination angle, spacing, and height of the fins 31.

[0299] A spatial topology relationship model of the fin 31 is constructed based on a graph neural network (GNN), and the fin 31 surface curvature distribution and gap width data are generated.

[0300] Based on the model, the coating path is broken down as follows: "The spray head 311 moves in the length direction X of the heat exchanger while simultaneously oscillating and sweeping coating in the width direction Y of the heat exchanger." The spray head 311 moves in the length direction X of the heat exchanger along a sinusoidal trajectory, and the amplitude and frequency of the spray head 311 are adaptively adjusted according to the gaps between the fins 31 to ensure that the coating penetrates to the roots of the fins 31 and does not clog the gaps.

[0301] A PID algorithm adjusts the compressed air pressure of the spray head 311 in real time to accommodate different fin 31 density areas, increasing the pressure in high density areas and decreasing the pressure in low density areas.

[0302] The mass flow meter 330 monitors the paint flow rate in real time, and if the deviation exceeds ±5%, an alarm is triggered to suspend painting, and the MES system records the abnormality.

[0303] The painting robot 310 moves along a planned path along the first rail 370, and the spray head 311 sprays atomized particles with a diameter of 0.3 mm to uniformly cover the surface of the fin 31.

[0304] After the coating is completed, the heat exchanger enters the UV curing unit 340, which uses 365nm wavelength and 500W / m 2 Irradiate at 1000 W for 30 seconds to complete the crosslinking and curing of the coating.

[0305] Painting parameters (such as paint thickness and repair agent content) are uploaded to the IoT platform via the OPC UA protocol and linked to the MES system to achieve quality tracking throughout the entire lifecycle.

[0306] In the above description of the embodiments, the particular features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or examples.

[0307] The above are specific embodiments of the present application, but the scope of protection of the present application is not limited thereto. Any modifications or replacements that a person skilled in the art can easily conceive within the technical scope disclosed in the present application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be determined by the scope of protection of the claims.

Claims

1. An air conditioner production, operation and maintenance system, The system includes a general-purpose heat exchanger production system, an indoor unit production system, a bending unit, an outdoor unit production system, a material storage system, a packaging system, a conveying system, and a control system; The heat exchanger general-purpose production system includes: an indoor heat exchanger fin production unit configured to produce indoor heat exchanger fins; an outdoor heat exchanger fin production unit configured to produce outdoor heat exchanger fins; a plurality of general-purpose heat exchanger production units configured to produce unfolded outdoor heat exchangers using the outdoor heat exchanger fins and heat exchanger material, and to produce indoor heat exchangers using the indoor heat exchanger fins and heat exchanger material; the indoor unit production system includes a plurality of indoor unit production units configured to produce indoor units using the indoor heat exchanger and indoor unit materials, the folding unit is configured to fold an unfolded outdoor heat exchanger onto the outdoor heat exchanger; the outdoor unit production system includes a plurality of outdoor unit production units configured to produce outdoor units using the outdoor heat exchanger and outdoor unit materials, the material storage system is configured to store the heat exchanger material, the indoor unit material, and the outdoor unit material; the packaging system is configured to receive and package the indoor unit and the outdoor unit; the conveying system is configured to convey the heat exchanger materials to the heat exchanger general-purpose production system, convey the indoor unit materials to the indoor unit production system, convey the outdoor unit materials to the outdoor unit production system, and convey packaging materials and the indoor units and outdoor units to the packaging system, and includes an overhead crane system; The overhead crane system includes: a rail, a portion of which is located above the heat exchanger general-purpose production system, the indoor unit production system, the outdoor unit production system, and the material storage system; an overhead crane located on the rail and including a gripping device and a position sensing device; the control system communicates with the heat exchanger general-purpose production system, the indoor unit production system, the outdoor unit production system, the material storage system, the packaging system, and the conveying system, and is configured to control the conveying system to convey materials, control the indoor heat exchanger fin production unit and the general-purpose production unit to produce indoor heat exchangers, control the indoor unit production system to produce indoor units using the indoor heat exchangers and indoor unit materials, control the outdoor heat exchanger fin production unit, the general-purpose production unit, and the bending unit to produce outdoor heat exchangers, control the outdoor unit production system to produce outdoor units using the outdoor heat exchangers and outdoor unit materials, and control the packaging system to package the materials and the indoor units and outdoor units; the indoor unit production system and the outdoor unit production system are arranged in parallel between the heat exchanger general-purpose production system and the material storage system, The rail is Overhead crane standby rail section, a material rail section positioned above the material storage system; a heat exchanger rail section positioned above the heat exchanger general production system; an indoor unit rail section located above the indoor unit production system; an outdoor unit rail section located above the outdoor unit production system; a packaging rail section positioned above the packaging system; a first rail section connecting the material rail section and the heat exchanger rail section and positioned between the indoor unit rail section and the outdoor unit rail section; a second rail section connecting the heat exchanger rail section and the indoor unit rail section; a third rail section connecting the first rail section and the indoor unit rail section; a fourth rail section connecting the indoor unit rail section and the overhead crane standby rail section; a fifth rail section connecting the first rail section and the outdoor unit rail section; a sixth rail section connecting the packaging rail section and the overhead crane standby rail section; a seventh rail section connecting the material rail section and the packaging rail section; the overhead crane is configured to travel up to the material rail section, grab the heat exchanger material, reach the heat exchanger rail section via the first rail section, release the heat exchanger material to the heat exchanger general-purpose production system, and then reach the fourth rail section via the second rail section and the indoor unit rail section; the overhead crane is configured to travel up to the material rail section, grab the indoor unit material, reach the indoor unit rail section via the first rail section and the third rail section, release the indoor unit material to the indoor unit production system, and then reach the fourth rail section; the overhead crane is configured to travel to the material rail section, grab the outdoor unit material, pass through the first rail section and the fifth rail section, reach the outdoor unit rail section, release the outdoor unit material to the outdoor unit production system, and then reach a sixth rail section; the material storage system is configured to store packaging material; the packaging system is located below a sixth rail section of the conveying system, and the material rail section and the sixth rail section are connected via a seventh rail section; An air conditioner production, operation, and maintenance system, wherein the overhead crane of the transport system is configured to travel to the material rail section to grasp the packaging material, release the packaging material onto the packaging system when it reaches above the packaging system via the seventh rail section, and then reach the overhead crane waiting rail section via the sixth rail section.

2. the overhead crane standby rail section is located between the fourth rail section and the material rail section, and between the sixth rail section and the material rail section; the fourth rail section and the sixth rail section may or may not be joined to one another; The air conditioner production, operation, and maintenance system according to claim 1 , wherein the overhead crane is configured to reach the overhead crane standby rail section after the transportation of the material is completed.

3. The overhead crane system includes: a material box configured to contain the material; The air conditioner production, operation, and maintenance system according to claim 1 , wherein the gripping device is configured to grip the material box.

4. The gripping device is connected to the overhead crane via a lifting mechanism, The gripping device a base connected to the lifting mechanism; a threaded shaft rotatably attached to the base; a screw shaft drive mechanism configured to drive the screw shaft so as to rotate; The air conditioner production, operation, and maintenance system according to claim 3, further comprising: a jig connected to the screw shaft.

5. The air conditioner production, operation, and maintenance system according to claim 4 , wherein the gripping device includes a jig position limiting member configured to limit the position of the jig.

6. The air conditioner production, operation, and maintenance system according to claim 1 , wherein the overhead crane includes arms positioned on both sides of the gripping device, and position sensing devices are installed at the bottom ends of the arms.

7. The air conditioner production, operation, and maintenance system according to claim 6, wherein the position sensing device is a laser scanning device.

8. the packaging system is located downstream of the outdoor unit production system, and the material storage system is located downstream of the indoor unit production system; The air conditioner production, operation, and maintenance system according to claim 1 , wherein a seventh rail section of the conveying system is located between the outdoor unit production system and the packaging system.

9. a completed machine storage system configured to store the completed machine packaged by the packaging system; The completed aircraft storage system includes: a completed machine inventory information acquisition unit configured to acquire completed machine inventory information and transmit it to a completed machine management system; a complete machine management system in communication with the control system; the transport system is configured to transport the completed machine that has been packaged by the packaging system to a completed machine storage system; Alternatively, the air conditioner production, operation, and maintenance system according to claim 1, wherein the material storage system is configured to store completed units that have been packaged by the packaging system.

10. The material storage system comprises: a material management system in communication with the control system; a material storage shelf configured to store the material; 2. The air conditioner production, operation, and maintenance system according to claim 1, further comprising: a material transport device that receives transport material information and transports the transport material to the transport system when a material on a material storage shelf is identified as a transport material.

11. The air conditioner production, operation, and maintenance system of claim 10, wherein the material transport device determines whether transport of the transported material has been completed, and after transport of the transported material has been completed, the material transport device transmits transport completion information to the material management system, and the transport system executes the transport.

12. The material storage system comprises: The air conditioner production, operation, and maintenance system according to claim 10, further comprising a material inventory information acquisition module configured to acquire material inventory information and transmit it to the material management system.

13. 11. The air conditioner production, operation, and maintenance system according to claim 10, wherein the material storage shelves include a heat exchanger material storage shelf, an indoor unit material storage shelf, an outdoor unit material storage shelf, and a packaging material storage shelf, and the material rail sections of the conveying system include a heat exchanger material rail section located above the heat exchanger material storage shelf, an outdoor unit material rail section located above the outdoor unit material storage shelf, an indoor unit material rail section located above the indoor unit material storage shelf, and a packaging material rail section located above the packaging material storage shelf.

14. 2. The air conditioner production, operation and maintenance system of claim 1, wherein the heat exchanger general-purpose production system, the indoor unit production system and the outdoor unit production system each include a sub-control system, which communicates with the control system, receives detection information from each of the production units and is used to control the operating status of each of the associated production units.

15. The heat exchanger general-purpose production system includes: an endplate information creating unit configured to create a unique identifier for each endplate as endplate information on the endplate; a production unit of the heat exchanger general-purpose production system including an information acquisition module configured to acquire end plate information arriving at the production unit; The indoor unit production system and the outdoor unit production system are a pallet information creating unit configured to create a unique identifier for each pallet as pallet information on the pallet; the production units of the indoor unit production system and the outdoor unit production system are provided with the information acquisition module configured to acquire information about pallets that have arrived at the production units; 2. The air conditioner production, operation, and maintenance system of claim 1, wherein the information acquisition module communicates with the control system, and the control system is configured to monitor end plate information and pallet information of the production unit, send them to the packaging system, and form a label traceability code to be affixed to the packaging system.

16. The air conditioner production, operation, and maintenance system of claim 15, wherein the control system is configured to send material information of the indoor unit or outdoor unit corresponding to the transported heat exchanger to the end plate information creation unit, and the end plate information creation unit is used to form a unique identifier of the end plate and the material information associated therewith as end plate information.

17. A production system comprising: a unit shelf positioned adjacent a production unit and configured to receive material conveyed from the conveying system; The air conditioner production, operation, and maintenance system according to claim 1 , wherein the unit shelf includes an identifier or a signal generator that is sensed by a position sensing device of the transport system.

18. The production unit comprises: an input device configured to input material from the unit shelf into the production unit; a material detection device configured to detect the quantity of material on the unit shelf; the control system is configured to control the conveying system to convey the material when the quantity of the material falls below a threshold; The air conditioner production, operation, and maintenance system according to claim 17, wherein, if the detection result of the detection unit is unacceptable, the transport system transports the material preceding the detection unit and reproduces the material preceding the detection unit.

19. a ground transfer device configured to receive control information from the control system and transfer assembled parts between units in accordance with the control information; a roller conveyor line used to connect the production units in each production system; The production unit comprises: a production unit status detection module configured to detect operation status information of the production unit equipment; The control system is used to determine or predict equipment failure based on the operating state information; The production unit comprises: Including unit lighting equipment that is always turned off, The control system is configured to turn on a unit lighting equipment corresponding to the production unit when it determines or predicts that the production unit equipment has failed, The air conditioner production, operation, and maintenance system further comprises: A detection unit configured to detect whether the product is passed or not, and if the detection result of the detection unit is a failure, the detection unit outputs the failure information through a failure product conveying line and transmits the failure information to the control system; The production, operation, and maintenance system for air conditioners according to claim 1 , wherein the control system controls the transport system to transport and reproduce materials upstream of the detection unit.

20. 2. A method for producing an air conditioner using the air conditioner production, operation, and maintenance system according to claim 1, comprising: Acquiring air conditioner demand information; determining a production process based on the air conditioner demand information; controlling the operating states of the heat exchanger general-purpose production system, the indoor unit production system, and the outdoor unit production system according to the production process; when producing outdoor units in the production process, controlling the outdoor heat exchanger fin production unit, the general-purpose production unit, and the bending unit to produce outdoor heat exchangers, the outdoor unit production system producing outdoor units; when producing indoor units in the production process, controlling the indoor heat exchanger fin production unit and the general-purpose production unit to produce indoor heat exchangers, the indoor unit production system producing indoor units; Based on the air conditioner demand information, the required number of indoor units and the required number of outdoor units corresponding to the model of air conditioner to be produced are determined, and the number n of indoor heat exchangers to be continuously produced is determined, where n is a natural number. Controlling a general-purpose heat exchanger production system to first produce one outdoor heat exchanger and supply it to the outdoor unit production system, and then producing n indoor heat exchangers and supplying them to the indoor unit production system; If the number of indoor units reaches the required number of indoor units but the number of outdoor units does not reach the required number of outdoor units, the production process is changed so that the general-purpose heat exchanger production system is controlled to produce outdoor heat exchangers and supply them to the outdoor unit production system; If the number of outdoor units reaches the required number of outdoor units but the number of indoor units does not reach the required number of indoor units, changing the production process to control the general-purpose heat exchanger production system to produce indoor heat exchangers and supply them to the indoor unit production system; Determining the quantity n of indoor heat exchangers to be continuously produced is determining a time t3 for producing the indoor units and a time t4 for producing the outdoor units based on the model of the air conditioner to be produced, and then dividing the time t4 by the time t3 and converting the result into an integer to determine n; Alternatively, the number n of indoor heat exchangers to be continuously produced may be set to the number n of indoor units included in one set of air conditioning system, If the production process is to produce an outdoor heat exchanger, control the outdoor heat exchanger fin production unit to produce the outdoor heat exchanger fin, the tube bending unit of the general-purpose production unit cuts the tube at a first cutting operation position, the operating frequency of the tube expanding unit of the general-purpose production unit is a first frequency, and the bending unit bends the unbent outdoor heat exchanger; If the production process is to produce an indoor heat exchanger, control the indoor heat exchanger fin production unit to produce the indoor heat exchanger fin, the tube bending unit of the general-purpose production unit to cut the tube at the second cutting operation position, the operating frequency of the tube expanding unit of the general-purpose production unit to be the second frequency, and the bending unit to be inactive; the second frequency is less than or equal to the first frequency; Obtaining air conditioner demand information is acquiring an order and acquiring air conditioner demand information based on the order; and / or predicting air conditioner demand information for future time periods based on historical data; an overhead crane of the transport system identifying a material storage location and loading the material; the overhead crane identifies the location of a target unit shelf and transfers the material to the target unit shelf; Detecting the quantity of material on the unit shelf, and controlling the conveying system to convey the material when the quantity of the material falls below a threshold; When the detection result of the detection unit is unacceptable, the conveying system conveys the material before the detection unit, and reproduces the material before the detection unit. detecting a part in a production system with the detection unit; If the detection unit detects a rejected part, outputting the rejected part from the production process via a rejected part conveying line and transmitting reject information to the control system; the control system responding to the rejection information to instruct a transport system to replenish production materials for an upstream process associated with the detection unit; After the planned production quantity of the current production process is completed, a replenishment production process is initiated to reproduce the parts corresponding to the rejected parts using the replenished production materials; the conveying system transmits conveyed material information to the control system; The end plate information creation unit of the heat exchanger general production system creates a unique identifier of each end plate as end plate information on the end plate, and the control system acquires the end plate information; A pallet information creation unit of the indoor unit production system or the outdoor unit production system creates a unique identifier for each pallet as pallet information on the pallet, and the control system acquires the pallet information; The control system associates the end plate information, pallet information, and transported material information, and records production product information and production process information; The control system transmits the transported material information to an end plate information creation unit, and the end plate information creation unit forms the material information and a unique identifier as end plate information and creates it on the end plate; Detecting the operating status information of production unit equipment, Determining or predicting equipment failure based on the operating state information; The lighting equipment in the production unit is controlled to be always off, When it is determined or predicted that the production unit equipment has failed, a unit lighting equipment corresponding to the production unit is turned on.

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